Ford - Expedition 4wd - Workshop Manual - 1998 - 1998

Factory Workshop Manual Make Ford Model Expedition 4wd Engine and year V8-281 4.6L SOHC (1998) 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 (V8-281 4.6L SOHC (1998)) 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 ( P 0500 ) P0500 - P0504: Testing and Inspection P0500 ( P 0500 ) For diagnosis of P0500 refer to the system experiencing the problem. Computers and Control Systems or Transmission Control System Refer to pinpoint test DP1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DP - Vehicle Speed Sensor (VSS) For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Transfer Case Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 ( P 0500 ) > Page 9 B1466 - P1815 GEM Trouble Code (DTC) For complete Transfer Case diagnostic information, See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Windshield Wiper Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 ( P 0500 ) > Page 10 For complete Windshield Wiper diagnostic information, See: Wiper and Washer Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1805 - P1809, ( P1806 P1807 P1808 1805 1806 1807 1808 1809 ) > System Information > System Diagnosis > P1808 P1805 - P1809: Testing and Inspection P1808 For diagnosis of P1808 refer to the system experiencing the problem. Suspension Control Air Suspension Diagnostic Trouble Code (DTC) Index, Part 1 Of 2 For complete Transfer Case diagnostic information, See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Instrument Panel Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1805 - P1809, ( P1806 P1807 P1808 1805 1806 1807 1808 1809 ) > System Information > System Diagnosis > P1808 > Page 16 Part 4 Of 5 For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 23 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Accessory Delay Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module Alarm Module: Locations Anti-Theft Transceiver Module Instrument Panel View The Anti Theft-Transceiver Module is located behind the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 28 Alarm Module: Locations Passive Anti-Theft System Module Body View The Passive Anti-Theft System Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 29 Alarm Module: Locations Remote Anti-Theft Personality Module Body Views Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 30 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module Passive Anti-theft System Control Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 33 Anti-theft Transceiver Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 34 Alarm Module: Diagrams Remote Anti-Theft Personality Module Remote Anti-Theft Personality Module (C257) Remote Anti-Theft Personality Module (C256) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Key Programming - New Key With Diagnostic Tool Alarm Module: Service and Repair Key Programming - New Key With Diagnostic Tool NOTE: Before starting this procedure, make sure the key(s) you want to program have the correct mechanical cut. 1. Plug in NGS tester (requires V10 card or higher). ^ (Or use V8.0 or higher and select DN101 4V as vehicle). 2. Turn the key to RUN. 3. If the key is already programmed, the THEFT indicator proves out after two seconds or if the key is not programmed, the THEFT indicator flashes rapidly. 4. Enter PATS Function Test and select ERASE IGNITION KEY. 5. TEST in PROGRESS will display on the screen. If a programmed key is being used, all keys will be erased within five seconds. If a non programmed key is being used, erasing will take a minimum of eight minutes. 6. TEST COMPLETE will display on screen. All keys are now erased. 7. Turn the key to OFF, and then back to RUN. 8. THEFT indicator proves out after two seconds. 9. PATS key is now programmed. 10. Additional keys may be programmed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Key Programming - New Key With Diagnostic Tool > Page 37 Alarm Module: Service and Repair Key Programming - New Key Without Diagnostic Tool NOTE: Before starting this procedure, make sure the key(s) you want to program have the correct mechanical cut. 1. Insert the non programmed key in the ignition and turn to RUN. 2. THEFT indicator flashes rapidly. 3. After 15 minutes of flashing, the THEFT indicator will stop flashing. 4. Within five minutes after the THEFT indicator has stopped flashing, turn the ignition key to OFF and back to RUN. 5. After 15 minutes of flashing, the THEFT indicator will stop flashing. 6. Within five minutes after the THEFT indicator has stopped flashing, turn the ignition key to OFF and back to RUN. 7. After 15 minutes of flashing, the THEFT indicator will stop flashing. 8. All originally programmed keys are now erased, and only the key in the ignition is programmed. 9. Additional keys may be programmed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Key Programming - New Key With Diagnostic Tool > Page 38 Alarm Module: Service and Repair Key Programming - Spare Key NOTE: ^ Before starting this procedure, make sure the key(s) you want to program have the correct mechanical cut. ^ Performing this procedure does not erase existing programmed keys. 1. Insert the programmed key in the ignition. Turn to RUN. 2. THEFT indicator proves out after two seconds. 3. Remove the programmed key. 4. Within 15 seconds, insert the new key in the ignition and turn to RUN. 5. THEFT indicator proves out after two seconds. 6. The extra key is now programmed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Key Programming - New Key With Diagnostic Tool > Page 39 Alarm Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the PATS module. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the PATS module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Key Programming - New Key With Diagnostic Tool > Page 40 The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. ^ All vehicle keys must now be programmed. The first key will automatically program, and the additional keys should follow spare key programming. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Specifications Multifunction Electronic Control Module: Specifications GEM Screws ........................................................................................................................................ ........................................... 0.9-1.3 N.m (8-12 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Specifications > Page 44 Multifunction Electronic Control Module: Locations Instrument Panel View The Generic Electronic Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 47 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 48 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 49 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 50 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 51 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 52 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 53 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 54 Multifunction Electronic Control Module: Connector Views Generic Electronic Module (C239) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 55 Generic Electronic Module (C267) Generic Electronic Module (C240) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 56 Generic Electronic Module (C241) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 57 Multifunction Electronic Control Module: Electrical Diagrams Generic Electronic Module (Part 1 Of 5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 58 Generic Electronic module (Part 2 of 5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 59 Generic Electronic module (Part 3 of 5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 60 Generic Electronic module (Part 4 of 5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 61 Generic Electronic module (Part 5 of 5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 62 Multifunction Electronic Control Module: Description and Operation The Generic Electronic Module (GEM) constantly monitors its subsystems for concerns. If a concern is found in one of the subsystems, the GEM will record the concern in the form of a Diagnostic Trouble Code (DTC). The ignition switch position is very important to the GEM function. Often times, erratic or unexpected GEM function can be traced to problems with these GEM inputs. The GEM controls the following features: ^ Wipers/washers (front/rear). ^ Warning chimes. ^ Battery saver. ^ Illuminated entry and courtesy lamps. ^ Driver power window. ^ Accessory delay. ^ 4-wheel drive. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 63 There are four modes of operation for the front wipers: speed dependent interval, slow, fast and wash. These modes are only active with the ignition switch in the RUN or ACC position. The two modes of operation for the rear wipers are interval and wash. These modes are only active with the ignition switch in the RUN or ACC positions and with both the liftgate and liftgate glass closed. The GEM controls five warning chimes and lamps: headlamps operating without the ignition on (chime only), door ajar (chime and lamp), key-in-ignition (chime only), driver seat safety belt warning (chime and lamp), and low washer fluid warning (chime and lamp). The battery saver feature removes extended interior lamp power drains from the battery. The GEM will keep power available for all interior lights and under hood lamp circuits for 40 minutes after the ignition switch is turned off. The GEM illuminates the interior courtesy lamps when any door is ajar. The GEM also provides illuminated entry when the unlock button is used to unlock the vehicle. The GEM illuminates the running board lamps when the interior lamps are activated (see courtesy lamps and illuminated entry description above) and the ignition switch is not in the RUN position. The delayed accessory feature provides power to the power windows for ten minutes after the ignition switch is moved from the RUN to the OFF position. If during this ten-minute period either front door is opened, the delayed accessory relay will be de-energized. This system is equipped with Automatic 4-Wheel Drive (A4WD). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Driver Seat Module Multifunction Electronic Control Module: Service and Repair Driver Seat Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the driver seat. 3. Disconnect the driver seat module electrical connectors. 4. Remove the screws from the driver seat module and release the module retainers from the module bracket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Driver Seat Module > Page 66 Multifunction Electronic Control Module: Service and Repair Generic Electronic Module (GEM) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the steering column opening cover. 3. Remove the (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel. 4. Remove the (A) instrument panel fuse junction panel bolts and remove the (B) interior fuse junction panel nuts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Driver Seat Module > Page 67 5. Disconnect the (A) GEM electrical connectors from the (B) GEM. 6. Remove the screws and the GEM. INSTALLATION NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 1. To install, reverse the removal procedure. ^ Check for proper operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications RAP Module Nuts ................................................................................................................................ ......................................................... 7 Nm (62 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 71 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 72 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 73 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Disconnect the C257 and C256 Remote Anti-theft Personality (RAP) module electrical connectors. 3. Remove the nuts and the RAP module. NOTE: On Expedition and later build Navigators, the antenna is internal to the module and must be replaced as an assembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 74 strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications RAP Module Nuts ................................................................................................................................ ......................................................... 7 Nm (62 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 79 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 80 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 81 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Disconnect the C257 and C256 Remote Anti-theft Personality (RAP) module electrical connectors. 3. Remove the nuts and the RAP module. NOTE: On Expedition and later build Navigators, the antenna is internal to the module and must be replaced as an assembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 82 strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay Power Door Lock Relay: Locations All Lock Relay Body View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 87 Lock Relays The All Lock Relay is located in lock relays. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 88 Power Door Lock Relay: Locations All Unlock Relay Body View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 89 Lock Relays The All Un-Lock Relay is located in lock relays. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 90 Power Door Lock Relay: Locations Driver's Door Unlock Relay Body View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 91 Lock Relays The Driver's Unlock Relay is located in the lock relays. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 92 Power Door Lock Relay: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Memory Power Driver Seat Operation Power Seat Control Module: Description and Operation Memory Power Driver Seat Operation The memory driver seat feature allows the driver to program a personalized seat position that can be recalled using the memory switches or remote entry key fob. There are three memory settings possible. The outside rear view mirror positions are also stored and recalled with the power driver seat positions. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 97 Power Seat Control Module: Description and Operation Memory Seat Module Driver Seat Module The power driver seat and power outside rear view mirrors are controlled by the Driver Seat Module (DSM) only when the vehicle is equipped with the programmable/recall memory option. The DSM system consists of the following components: ^ Driver seat module. ^ Driver memory seat switch. ^ Memory mirror switch. ^ Memory set switch. ^ Front vertical seat motor. ^ Rear vertical seat motor. ^ Driver horizontal seat motor. ^ LH heated memory mirror. ^ RH heated memory mirror. The DSM incorporates multiple functions into one module and offers diagnostics to easily locate and repair concerns affecting the subsystems that it controls. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 98 Power Seat Control Module: Description and Operation Programming Seat Positions A power driver seat position can be stored at any time. The driver must move the seat to the desired position using the driver seat switch assembly. The driver must then depress the memory SET switch which activates the memory SET switch Light Emitting Diode (LED). Within five seconds (before the LED goes out), the driver must select a memory position. Memory 1 is selected by depressing memory switch 1. Memory 2 is selected by depressing memory switch 2. Memory 3 is selected by depressing both memory switch 1 and memory switch 2 simultaneously. If no memory switch input is received within the five second time limit, the operation is aborted and the memory SET switch LED is turned off. If one of the following inputs is received during the five secondprogramming limit, the operation is aborted and the memory SET switch LED is turned off: - Power driver seat switch. - Power outside rear view mirror switch. - Memory SET switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 99 Power Seat Control Module: Description and Operation Recalling A Stored Seat Position NOTE: A memory recall can be initiated only if the vehicle is in PARK or NEUTRAL gear and the ignition switch is not in START. A memory recall in progress will not be affected by moving the ignition switch to START or by moving the gearshift lever out of PARK or NEUTRAL. Once the driver has stored the desired driver seat position, the driver can recall the setting by depressing the corresponding memory switch or by using a programmed remote entry transmitter. ^ The driver can recall the desired driver seat position by depressing one or both of the memory recall switches. Depressing memory switch 1 will initiate a recall of the power driver seat position stored in memory 1. Depressing memory switch 2 will initiate a recall of the power driver seat position stored in memory 2. Depressing memory switch 1 and memory switch 2 simultaneously will initiate a recall of the power driver seat position stored in memory 3. ^ A remote transmitter can be used to recall previously set memory positions. Transmitters are manufactured with an assigned personality number (1, 2, or 3) and are so designated on the back of the transmitter. The transmitter assigned with personality 1 is capable of recalling memory position 1 only. Similarly, the personality 2 and 3 transmitters can recall only memory positions 2 and 3 respectively. ^ Memory recall occurs when the UNLOCK switch is depressed on the transmitter. The second depression of the UNLOCK switch, which unlocks passenger doors, does not initiate a memory recall. ^ A memory recall in progress does not prohibit the initiation of another memory recall; the most recently requested memory recall will be executed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations Sunroof / Moonroof Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 103 RPO Relay Block The Vent Window/Moonroof Relay is located in the regular production option relay block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 104 Sunroof / Moonroof Relay: Testing and Inspection Relay Component Test Testing of an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove (unplug) the relay to be tested from the engine compartment fuse junction panel, I/P fuse junction panel or individual connector. Mini ISO Relay Use 73 Digital Multimeter to check for the continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 85 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. With 73 Digital Multimeter set in the volts position, check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85 and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair Sunroof / Moonroof Module: Service and Repair REMOVAL 1. Close the sliding roof panel. 2. Disconnect the battery ground cable. 3. Remove the access cover. 4. Slide the sliding roof panel module from the retaining bracket. 5. Disconnect the electrical connectors and remove the sliding roof panel module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 112 Power Distribution Relay Box The 4 Wheel Anti-Lock Brake System Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored Electronic Brake Control Module: Customer Interest ABS - Lamp ON/DTC B1342 Stored Article No. 98-9-15 05/11/98 ^ BRAKES - 4WABS - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL VEHICLES BUILT THROUGH 2/12/98 ^ LAMP - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL - VEHICLES BUILT THROUGH 2/12/98 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B1342 may be stored in memory and/or New Generation Star (NGS) Tester may read "Invalid Code." This may be caused by the Nonvolatile Random Access Memory (NVRAM) chip inside the anti-lock brake control module not resetting at low residual voltages. ABS brake function may become inoperative, however, normal braking operation will be maintained. ACTION Replace the anti-lock brake control module. Modules with a build date of 2/19/98 or later have been revised to incorporate a new NVRAM chip. Refer to the appropriate Workshop Manual, Section 206-09, for replacement procedures. PART NUMBER PART NAME F75Z-2C065-AA Anti-lock Brake Control Module (F-150) F75Z-20065-BA Anti-lock Brake Control Module (F-250 LD) F7SZ-2C065-CA Anti-lock Brake Control Module (Expedition, Navigator) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980915A Diagnose And Replace 0.6 Hr. ABS Module - F-Series, Expedition, And Navigator DEALER CODING CONDITION BASIC PART NO. CODE 2C065 42 OASIS CODES: 206000, 301000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored Electronic Brake Control Module: All Technical Service Bulletins ABS - Lamp ON/DTC B1342 Stored Article No. 98-9-15 05/11/98 ^ BRAKES - 4WABS - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL VEHICLES BUILT THROUGH 2/12/98 ^ LAMP - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL - VEHICLES BUILT THROUGH 2/12/98 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B1342 may be stored in memory and/or New Generation Star (NGS) Tester may read "Invalid Code." This may be caused by the Nonvolatile Random Access Memory (NVRAM) chip inside the anti-lock brake control module not resetting at low residual voltages. ABS brake function may become inoperative, however, normal braking operation will be maintained. ACTION Replace the anti-lock brake control module. Modules with a build date of 2/19/98 or later have been revised to incorporate a new NVRAM chip. Refer to the appropriate Workshop Manual, Section 206-09, for replacement procedures. PART NUMBER PART NAME F75Z-2C065-AA Anti-lock Brake Control Module (F-150) F75Z-20065-BA Anti-lock Brake Control Module (F-250 LD) F7SZ-2C065-CA Anti-lock Brake Control Module (Expedition, Navigator) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980915A Diagnose And Replace 0.6 Hr. ABS Module - F-Series, Expedition, And Navigator DEALER CODING CONDITION BASIC PART NO. CODE 2C065 42 OASIS CODES: 206000, 301000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 126 Electronic Brake Control Module: Specifications TORQUE SPECIFICATIONS Control Module Screws .............................................................................................................................................................. 4-5 Nm (36-44 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 127 Electronic Brake Control Module: Locations Engine View The 4 Wheel Anti-Lock Brake System Module is located at the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 128 Electronic Brake Control Module: Diagrams 4 Wheel Anti - Lock Brake System Module ( C146) 4 Wheel Anti - Lock Brake System Module (C147) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 129 Electronic Brake Control Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the two anti-lock brake control module electrical connectors. 3. Disconnect the pump motor electrical connector from the ABS module. 4. Remove the anti-lock brake control module. 1 Remove the screws. 2 Remove the anti-lock brake control module. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 130 1. To install, reverse the removal procedure. CAUTION: Ensure that the replacement anti-lock brake control module identification sticker reads EXP. Use of any other module could result in diminished ABS performance. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Engine View The Cooling Fan Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams Speed Control Servo/Amplifier Assembly Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 143 Blower/Flasher Relay Block The Blower Relay is located in the blower/flasher relay block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations As shown in the wiring diagrams, these vehicles do not use a compressor cut-off (also called a wide open throttle or WOT) relay. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control Control Module HVAC: Description and Operation Blower Motor Speed Control The A/C blower motor speed control is a Pulse Width Modulated (PWM) type which provides variable blower speed control of the blower motor. The A/C blower motor speed control is controlled by switching the control signal voltage of 5 volts OFF and ON 2,000 times per second. By varying the ratio of time on (+5 volts) to time off (0 volts), the EATC module tells the A/C blower motor speed control how fast the blower motor should run. The A/C blower motor speed control has the following features: - Controls the speed of the blower motor by switching the motor OFF and ON 40,000 times per second by varying the ratio of time ON (+14 volts) to time OFF (0 volts). - Has circuitry to protect the blower motor from burning out in the event of a locked rotor condition. - Can compensate for changes in battery positive voltage (B+) which prevents the blower speed from slowing down when the engine is idling and will provide up to a maximum of 30 amperes for blower motor operation with battery voltages between 10 and 16 volts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control > Page 151 Control Module HVAC: Description and Operation Electronic Climate Control Module The Electronic Automatic Temperature Control (EATC) module, located in the instrument panel, has the following features: - 11 push buttons - a blower speed override thumbwheel for manual input - a vacuum fluorescent display for displaying set temperature, ambient temperature, function and Diagnostic Trouble Codes (DTCs) - an On-Board Diagnostic (OBD) feature to supply the technician with Diagnostic Trouble Codes (DTCs). These DTCs direct the technician to the inoperative component. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control Control Module HVAC: Service and Repair Blower Motor Speed Control REMOVAL 1. Disengage the stops and lower the glove compartment door. 2. Disengage the blower motor speed control mounting bracket from the instrument panel. 3. Disconnect the connectors. 4. Disengage the retaining tabs and remove the blower motor speed control from the mounting bracket. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 154 Control Module HVAC: Service and Repair Electronic Climate Control Module REMOVAL 1. Disconnect the battery ground cable. 2. Remove the center instrument panel finish panel. - Carefully pry to release the four clips. 3. Disconnect the control switch connector. 4. Remove the screws from the electronic automatic temperature control module. 5. Remove the electronic automatic temperature control module. 1 Disconnect the electrical connectors. 2 Remove the nuts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 155 3 Disconnect the vacuum harness connector and remove the EATC module. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 156 Control Module HVAC: Service and Repair Illumination Bulbs REMOVAL 1. Remove the control assembly. 2. Unsnap the bezel and pivot it open. - To replace the general illumination bulbs, unscrew the lamp holders and remove the bulb. - To replace the HI/LO bulb, cut the wires close to the bulb base, splice the wires to the new bulb and wrap the splice with electrical tape. NOTE: Place the module upside-down on a non-marring surface. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Testing and Inspection Speedometer Module: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Locations Battery Saver Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Locations > Page 165 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Battery Saver Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Locations > Page 166 Battery Saver Relay: Description and Operation The following components are controlled by the battery saver relay: - Interior lamps - Under hood lamp - Glove compartment lamp - Interior lamp relay - Accessory delay relay - Illuminated vanity mirrors (Navigator only) The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake mode, or in the sleep mode, (relay coil is de-energized). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Interior Lamp Relay Courtesy Lamp Relay: Locations Interior Lamp Relay Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Interior Lamp Relay > Page 171 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Interior Lamp Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Interior Lamp Relay > Page 172 Courtesy Lamp Relay: Locations Running Board Lamp Relay Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Interior Lamp Relay > Page 173 RPO Relay Block The Running Board Relay is located in the regular production option relay block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications Daytime Running Lamp Control Unit: Specifications Daytime Running Lamps Control Module Bolt ............................................................................................................................... 2.5-3.1 Nm (22-28 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 177 Daytime Running Lamp Control Unit: Locations Engine View The Daytime Running Lamps (DRL) Control Module is located on the radiator support. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 178 Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 179 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Remove the daytime running lamps control module from the radiator support. 1 Remove the bolt. 2 Disconnect the electrical connector. 3 Remove the daytime running lamps control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Locations Exterior Lighting Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Locations > Page 184 RPO Relay Block The Park Lamp Relay is located in the Regular Production Option relay block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 188 Power Distribution Relay Box The Fog Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Locations Headlamp Control Module: Locations Instrument Panel View The Autolamp Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Locations > Page 192 Autolamp Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 196 RPO Relay Block The Headlamp Relay is located in Regular Production Option relay block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 200 Power Distribution Box The Horn Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 201 Horn Relay: Testing and Inspection 1. Measure the resistance between relay terminal 85 and all other terminals. If any resistance is 5 ohms or less, replace the relay. Otherwise, continue with the test. 2. Use jumper wires to apply battery voltage to terminals 30 and 85. Measure voltage at terminal 87A. If voltage is less than 10 volts, replace the relay. Otherwise, continue with the test. 3. Use a jumper wire to apply ground to terminal 86. Measure the voltage at terminal 87. If the voltage is less than 10 volts, replace the relay. Otherwise, return to the pinpoint tests. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations Interior Lighting Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 205 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Interior Lamp Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 206 Interior Lighting Relay: Description and Operation The GEM controls the interior lamps illuminated entry function by activating the interior lamp relay. The relay is activated by applying ground to the relay coil through C267-15, and is deactivated by removing the ground signal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay Trailer Lighting Relay: Locations Trailer Tow Backup Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 211 The Trailer Tow Backup Lamp Relay is located in the Power Distribution Box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 212 Trailer Lighting Relay: Locations Trailer Tow Battery Charge Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 213 The Trailer Tow Backup Lamp Relay is located in the Power Distribution Box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 214 Trailer Lighting Relay: Locations Trailer Tow Left Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 215 The Trailer Tow Backup Lamp Relay is located in the Power Distribution Box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 216 Trailer Lighting Relay: Locations Trailer Tow Right Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 217 The Trailer Tow Backup Lamp Relay is located in the Power Distribution Box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay Power Distribution Relay: Locations Trailer Tow Backup Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 223 Power Distribution Relay Box The Trailer Tow Backup Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 224 Power Distribution Relay: Locations Trailer Tow Battery Charge Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 225 Power Distribution Relay Box The Trailer Tow Battery Charge Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 226 Power Distribution Relay: Locations Trailer Tow Left Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 227 Power Distribution Relay Box The Trailer Tow Left Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 228 Power Distribution Relay: Locations Trailer Tow Right Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 229 Power Distribution Relay Box The Trailer Tow Right Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 230 Power Distribution Relay: Locations Trailer Tow Running Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 231 Power Distribution Relay Box The Trailer Tow Running Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block Relay Box: Locations Blower/Flasher Relay Block Instrument Panel View The Blower/Flasher Relay Block is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 236 Relay Box: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 237 Relay Box: Locations Regular Production Option Relay Block Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Blower/Flasher Relay Block Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 240 Lock Relays Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 241 Power Distribution Relay Box Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 242 RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Page 249 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 (V8-281 4.6L SOHC (1998)) 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 > Page 250 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 (V8-281 4.6L SOHC (1998)) 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 > Page 251 Engine Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Page 252 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 253 Engine Control Module: Specifications Powertrain Control Module (PCM) Electrical Connector Bolt ................................................................................................ 5.2-7.2 Nm (46.3-64.2 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 254 Engine Control Module: Locations The Powertrain Control Module is located below the dash, in the right side kick panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 257 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 258 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 259 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 260 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 261 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 262 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 263 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 264 Engine Control Module: Connector Views Power control module (part 1 of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 265 Power control module (part 2 of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 266 Power control module (part 3 of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Powertrain Control Modules (PCMs) are reprogrammable to update calibration levels without having to replace the PCM. The reprogramming may be performed with the PCM installed in the vehicle using the Service Bay Technical System (SBTS). The PCM may also be reprogrammed outside of the vehicle using the New Generation STAR (NGS) and a 15- to 104- Pin Flash Cable (007-00587 or equivalent). The Flash Cable connects between the NGS and the PCM. The proper calibration must be downloaded to the Data Transfer Card through the SBTS. Follow the download instructions displayed on the NGS screen. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 269 Engine Control Module: Reset Procedure NOTE: All OBD II scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears oxygen sensor test data. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation STAR (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTC's. New Generation STAR and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. To reset Keep Alive Random Access Memory, disconnect the battery ground cable for a minimum of 5 minutes. Resetting Keep Alive RAM will clear learned values the PCM has stored for adaptive systems such as idle and fuel trim. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 270 Engine Control Module: Removal and Replacement REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Loosen the bolt and disconnect the electrical connectors. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Remove the bracket clip. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 271 6. Remove the Powertrain Control Module (PCM). INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Main Relay (Computer/Fuel System): Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 275 Power Distribution Box The Powertrain Control Module Power Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 280 Power Distribution Box The Fuel Pump Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Main Relay (Computer/Fuel System): Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 284 Power Distribution Box The Powertrain Control Module Power Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations The ignition control module is integrated within the powertrain control module. It is not a separately replaceable component. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Locations > Page 289 Ignition Control Module: Description and Operation PURPOSE - The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM). The ICM receives engine position and speed information from within the crankshaft position sensor and desired spark advance information from the PCM. OPERATION - The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use within The PCM. - The PCM uses this information to determine which ignition coil to fire, calculating the turn ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Air Bag Diagnostic Monitor Screws ..................................................................................................................................... 10.2-13.8 N.m (90-122 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 294 Air Bag Control Module: Locations Instrument Panel View The Air Bag Diagnostic Monitor is located behind right side (Passenger Side) of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 295 Air Bag Control Module: Diagrams Air Bag Diagnostic Monitor (C208) Air Bag Diagnostic Monitor (C209) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 296 Air Bag Control Module: Description and Operation WARNING: UNDER NO CIRCUMSTANCES SUBSTITUTE ANOTHER FUSE VALUE FOR THE 10 A BATTERY FUSE. ANY FUSE OTHER THAN 10 A CAN CAUSE DISARMING FAILURE AND CAN RESULT IN DANGER TO THE OCCUPANTS OF THE VEHICLE. DO NOT ATTEMPT TO REPLACE THE 10 A BATTERY FUSE UNTIL THE AIR BAG SYSTEM FIRST HAS BEEN DEACTIVATED. REFER TO DEACTIVATION PROCEDURE. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Arming and Disarming NOTE: The safing sensor is internal to the air bag diagnostic monitor and is not replaced separately. The air bag diagnostic monitor continually monitors all air bag Supplemental Restraint System (SRS) components and wiring connections for possible faults in the system. If the air bag diagnostic monitor detects a fault in the SRS when the ignition switch is in the RUN position, a Lamp Fault Code (LFC) will be displayed by the air bag indicator, located on the instrument cluster. The air bag diagnostic monitor does not deploy the air bag in the event of a collision. The LH or RH air bag sensor and the safing sensor determine when to deploy the air bag. The air bag diagnostic monitor illuminates the air bag indicator for approximately six seconds when the ignition switch is in the RUN position and then turns the indicator off. This shows that the air bag indicator is operational. If the air bag indicator does not illuminate or the indicator stays on or flashes at any time, a fault has been detected by the air bag diagnostic monitor. LFCs may not be displayed for approximately 30 seconds after the ignition switch is placed in the RUN position. This is the amount of time the air bag diagnostic monitor requires to perform all tests and verify system faults. Each LFC (a series of flashes and pauses of the air bag indicator): ^ represents a two-digit number. ^ is always displayed at least twice. If the air bag diagnostic monitor detects a fault in the SRS, a Diagnostic Trouble Code (DTC) will be written to the air bag diagnostic monitor non-volatile RAM (NVRAM). This DTC will then cause the air bag diagnostic monitor to flash an LFC on the air bag indicator. DTCs can be retrieved with the New Generation Star (NGS) Tester. After repair, the DTC can then be cleared from the NVRAM. If a system fault is present and the air bag indicator is malfunctioning, an audible chime will be heard. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS requires repair. If a fault exists that makes unwanted air bag deployment possible, the air bag diagnostic monitor will attempt to remove deployment power by turning on a solid state switch to blow the 10 A battery Fuse 2. If the 10 A battery fuse has successfully been blown by the air bag diagnostic monitor, the air bag diagnostic monitor will not attempt to blow it again until the proper fault has been repaired and cleared. The air bag diagnostic monitor will store both the unwanted deployment DTC and the loss of deployment power DTC. The loss of deployment power DTC is the highest priority. DTCs are prioritized numerically. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. The air bag diagnostic monitor includes an internal backup power supply. This feature provides sufficient backup power to deploy the air bag in the event the battery or battery cables are damaged in a collision before safing and air bag sensors close. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 297 Air Bag Control Module: Service and Repair REMOVAL WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: The safing sensor is internal to the air bag diagnostic monitor and is not replaced separately. 1. Disconnect the battery ground cable. 2. Remove the RH cowl side trim panel. 3. Remove the air bag diagnostic monitor 1. Disconnect the two electrical connectors. 2. Remove the screws. 3. Remove the air bag diagnostic monitor. INSTALLATION 1. Follow the removal procedure in reverse order. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications Starter Relay: Specifications Starter Motor Solenoid Relay Switch Bolts ........................................................................................................................................ 7-9 N.m (62-79 Lb-In) Starter Motor Solenoid Relay Switch Terminal Nuts ........................................................................................................................ 5-11 N.m (45-97 Lb-In) Starter Motor Solenoid Relay Switch Cable Nuts .......................................................................................................................... 5-11.2 N.m (44-99 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications > Page 302 Starter Relay: Locations Engine View The Starter Motor Relay is located at the right rear of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications > Page 303 Starter Relay: Description and Operation The starter motor solenoid relay switch: ^ Receives a start signal from the ignition switch as long as the digital Transmission Range (TR) sensor is in the PARK or NEUTRAL position. ^ Switches battery power to the starter motor solenoid S terminal when it receives the START signal from the ignition switch which allows the starter motor to engage and start the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications > Page 304 Starter Relay: Service and Repair REMOVAL WARNING: WHEN PERFORMING 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 THE MAINTENANCE IS COMPLETE. 1. Disconnect the battery ground cable. 2. Remove the relay cover. 3. Disconnect the starter motor solenoid relay switch wires and cables. 1. Remove the insulator. 2. Disconnect the ignition switch signal wire. 3. Remove the nuts. 4. Remove the engine control sensor wire and the generator wire. 5. Remove the battery cables. 4. Remove the bolts and remove the starter motor solenoid relay switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications > Page 305 1. Follow the removal procedure in reverse order. WARNING: WHEN PERFORMING 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 THE MAINTENANCE IS COMPLETE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Instrument Panel View The Electronic Variable Orifice Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Locations > Page 311 Electronic Variable Orifice Steering Module (Without Air Suspension) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Locations > Page 312 Steering Control Module: Description and Operation Vehicles with air suspension use the air suspension control module to monitor steering control for the Electronic Variable Orifice (EVO) steering system. Vehicles with base suspension use the EVO control module to monitor the steering system. Both systems on a panic or aggressive turn will provide additional power assist. If there is any electrical system failure in the EVO system the system will default to full power assist. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations Engine View The Air Suspension Solid State Compressor Relay is located near the right headlamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 317 Compressor/Pump Relay: Description and Operation The compressor relay is energized by the control module to have high current flow from the battery to the compressor motor. - A Solid State Relay is used in the air suspension system for compressor control. The relay incorporates a custom power MOSFET and ceramic hybrid circuitry. The relay switches high current loads in response to low power signals and is controlled by the logic of the control module. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 326 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 327 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: Customer Interest Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 337 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 338 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: All Technical Service Bulletins Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 343 Suspension Control Module: Locations Instrument Panel View The 4 Wheel Air-Suspension Module is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 344 Suspension Control Module: Diagrams 4 Wheel Air Suspension Module (C295) 4 Wheel Air Suspension Module (C296) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 345 Suspension Control Module: Description and Operation A microcontroller-based electronic air suspension control module controls the air compressor motor (through a solid state relay), and all system solenoids. The air suspension control module also provides power to front and rear height sensors. The air suspension control module controls vehicle height adjustments by monitoring the two height sensors, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals, and the Brake Pedal Position (BPP) switch. The air suspension control module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing of the vehicle and related components. The air suspension control module is mounted in the passenger compartment inside the instrument panel, above the radio and temperature controls. The air suspension control module is interchangeable between the RAS and 4WAS system. The air suspension control module monitors and controls the system through a 32-pin two-way connector. The air suspension control module is keyed so that it cannot be plugged into an incorrect harness. There are two sides of the harness connection to the air suspension control module. Each is uniquely colored and keyed to prevent reversing the connections. NOTE: - The 4-Wheel Air Suspension (4WAS) control module is also used for the Rear Air Suspension (RAS) system. The internal processor recognizes external circuitry to determine if it is installed in a 4WAS or a RAS system. - The air suspension control module is calibrated with information from the air suspension height sensors. A new or swapped air suspension control module requires the ride height adjustment calibration process to be performs Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 346 Suspension Control Module: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. Remove the center instrument panel finish panel. 4 3. Disconnect the transfer case rotary control switch electrical connector. 4. Remove the steering column cover trim panel. 5. Remove the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 347 6. Remove the LH instrument panel finish panel. (1) Remove the seven bolts. (2) Disconnect the electrical connector. (3) Remove the instrument panel finish panel. 7. Remove the instrument cluster panel. (1) Remove the five screws. (2) Disconnect the four electrical connectors. (3) Remove the instrument cluster panel. 8. Remove the air suspension control module screws. 9. Remove the air suspension control module. (1) Disconnect the electrical connectors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 348 (2) Remove the air suspension control module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. - The air suspension control module is calibrated with information from the ride height sensor. A new or exchanged air suspension control module requires that the ride height adjustment calibration process be performed; refer to Front Ride Height Resetting-Clear B2140 DTC. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay Instrument Panel View The Torque On Demand Relay is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 355 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay Instrument Panel View The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay Torque On Demand Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay > Page 358 Transfer Case Shift Relays Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Description and Operation Heated Glass Control Module: Description and Operation The GEM controls the heated backlight grid and heated mirrors by controlling the state of the heated backlight/mirror relay. When the heated backlight/mirror switch is pressed, the GEM will activate the heated backlight/mirror relay. When the heated backlight/mirror relay is active, both the heated backlight grid and heated mirror elements will be energized. The GEM will deactivate the heated backlight/mirror relay when one of the following conditions is met: ^ The heated backlight/mirror switch is pressed when the feature is active. ^ Ignition switch state is changed from RUN to OFF/LOCK. ^ The 10 minute timing function is completed. Feature Inputs: ^ Ignition switch RUN position (12V on both RUN and RUN/ACC inputs). ^ Heated backlight/mirror switch (momentary contact to ground when switch is pressed). Feature Outputs: ^ Heated backlight/mirror relay control (grounded when activated, open circuit when deactivated). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Description and Operation Heated Glass Element Relay: Description and Operation The GEM controls the heated backlight grid and heated mirrors by controlling the state of the heated backlight/mirror relay. When the heated backlight/mirror switch is pressed, the GEM will activate the heated backlight/mirror relay. When the heated backlight/mirror relay is active, both the heated backlight grid and heated mirror elements will be energized. The GEM will deactivate the heated backlight/mirror relay when one of the following conditions is met: ^ The heated backlight/mirror switch is pressed when the feature is active. ^ Ignition switch state is changed from RUN to OFF/LOCK. ^ The 10 minute timing function is completed. Feature Inputs: ^ Ignition switch RUN position (12V on both RUN and RUN/ACC inputs). ^ Heated backlight/mirror switch (momentary contact to ground when switch is pressed). Feature Outputs: ^ Heated backlight/mirror relay control (grounded when activated, open circuit when deactivated). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Description and Operation Power Window Control Module: Description and Operation The Generic Electronic Module (GEM) controls the opening of the LF driver side power window (window down motion) by activating the One Touch Down (OTD)relay. There are two modes of window down operation, manual and auto mode. The manual mode is selected by pressing the LF window switch to the first (down) position. In manual mode the window will move downward only while the switch is depressed. When the LF window switch is pressed to the second (down) position, it enters auto mode and the window will open completely with just a momentary press of the switch. The GEM will activate the OTD Relay until one of the following conditions is met: - The LF regulator control switch is pushed to the UP position. - The LF regulator control switch is released (OFF position) and then moved to the down position (first detent) or one touch down position (second detent). - Seven seconds have elapsed since the OTD was initiated. - A window regulator electric drive stall condition is detected on the one touch down sense line inputs. The UP window operation is not controlled by the GEM. The feature is activated when the delayed accessory is active and the LF window regulator control switch is pressed to the UP position. The switch provides delayed accessory power to one side of the motor and ground to the other side through the one touch down relay. The one touch down relay is not active when the LF regulator control switch is in the UP position. Passenger windows may be raised or lowered using the LF master control switches or the appropriate passenger window switch. Passenger window switches receive power when the delayed accessory relay is active and the LF remote lock-out switch is in the UNLOCK position. When in the LOCK-OUT position, the passenger windows are deactivated. The GEM controls manual down and auto down window movement with the down window relay. The relay is activated by applying ground directly to one side of the down window relay coil, and deactivated by removing the ground signal. The delayed accessory relay provides power for the operation of the power windows and the power moon roof. The delayed accessory feature is active when the ignition switch is in the RUN or the ACC position, or when the ignition switch is changed from RUN or ACC to the OFF/LOCK position and the LF and RF doors are closed. The GEM will deactivate the delayed accessory feature when: - The LF door is ajar and the ignition switch is in the OFF/LOCK or KEY-OUT position. - The RF door is ajar and the ignition switch is in the OFF/LOCK or KEY-OUT position. - 10 minutes have elapsed since the ignition switch was changed from ACC or RUN to the OFF/LOCK position. Feature Inputs: - LF door open warning switch (open circuit with door closed, grounded with door ajar). - RF door open warning switch (open circuit with door closed, grounded with door ajar). - Ignition switch RUN position (battery potential on both the RUN and RUN/ACC inputs). - Ignition switch ACC position (battery potential on the RUN/ACC input). - Ignition switch OFF/LOCK position (absence of battery potential on the RUN, RUN/ACC, and START inputs). Feature Outputs: - Delayed accessory relay (grounded when activated, open circuit when deactivated). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 372 Junction Box Fuse/Relay Panel (Part 1 Of 2) The One Touch Down Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay Windshield Washer Relay: Locations Front Washer Pump Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 378 Power Distribution Box The Front Washer Pump Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 379 Windshield Washer Relay: Locations Rear Washer Pump Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 380 Power Distribution Relay Box The Rear Washer Pump Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay Wiper Relay: Locations Rear Wiper Down Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 385 Power Distribution Relay Box The Rear Wiper Down Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 386 Wiper Relay: Locations Rear Wiper Up Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 387 Power Distribution Relay Box The Rear Wiper Up Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 388 Wiper Relay: Locations Wiper High/Low Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 389 Power Distribution Box The Wiper High-Low Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 390 Wiper Relay: Locations Wiper Run/Park Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 391 Power Distribution Box The Wiper Run/Park Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Door Left Power Door Lock Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Door > Page 398 Right Power Door Lock Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: Customer Interest Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: All Technical Service Bulletins Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 415 Power Seat Switch: Specifications Seat Regulator Control Switch Screws ................................................................................................................................................... 1-3 Nm (9-26 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 416 Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 417 Power Seat Switch: Testing and Inspection Left Front Seat Control Switch - Component Testing Procedure (Part 1 Of 2) Left Front Seat Control Switch - Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 418 Left Front Seat Control Switch - Terminal Locations Left Front Seat Control Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 419 Power Seat Switch: Service and Repair REMOVAL NOTE: Driver side shown, passenger side similar. 1. Disconnect the battery ground cable. 2. Remove the front seat back adjust handle. 1 Remove the screw. 2 Remove the front seat back adjust handle. 3. Pull to remove the front seat lumbar support handle. 4. Remove the front seat track shield screws. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 420 5. Remove the pushpin on the back of the front seat track shield. 6. Remove the screws on the bottom of the front seat track shield. 7. Disconnect the seat regulator control switch from the front of the front seat track shield. 1 Remove the screws. 2 Disconnect the seat regulator control switch. 8. Disconnect the seat regulator control switch electrical connector and remove the seat regulator control switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 421 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Description and Operation > Memory Power Driver Seat Operation Seat Memory Switch: Description and Operation Memory Power Driver Seat Operation The memory driver seat feature allows the driver to program a personalized seat position that can be recalled using the memory switches or remote entry key fob. There are three memory settings possible. The outside rear view mirror positions are also stored and recalled with the power driver seat positions. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 426 Seat Memory Switch: Description and Operation Programming Seat Positions A power driver seat position can be stored at any time. The driver must move the seat to the desired position using the driver seat switch assembly. The driver must then depress the memory SET switch which activates the memory SET switch Light Emitting Diode (LED). Within five seconds (before the LED goes out), the driver must select a memory position. Memory 1 is selected by depressing memory switch 1. Memory 2 is selected by depressing memory switch 2. Memory 3 is selected by depressing both memory switch 1 and memory switch 2 simultaneously. If no memory switch input is received within the five second time limit, the operation is aborted and the memory SET switch LED is turned off. If one of the following inputs is received during the five secondprogramming limit, the operation is aborted and the memory SET switch LED is turned off: - Power driver seat switch. - Power outside rear view mirror switch. - Memory SET switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 427 Seat Memory Switch: Description and Operation Recalling A Stored Seat Position NOTE: A memory recall can be initiated only if the vehicle is in PARK or NEUTRAL gear and the ignition switch is not in START. A memory recall in progress will not be affected by moving the ignition switch to START or by moving the gearshift lever out of PARK or NEUTRAL. Once the driver has stored the desired driver seat position, the driver can recall the setting by depressing the corresponding memory switch or by using a programmed remote entry transmitter. ^ The driver can recall the desired driver seat position by depressing one or both of the memory recall switches. Depressing memory switch 1 will initiate a recall of the power driver seat position stored in memory 1. Depressing memory switch 2 will initiate a recall of the power driver seat position stored in memory 2. Depressing memory switch 1 and memory switch 2 simultaneously will initiate a recall of the power driver seat position stored in memory 3. ^ A remote transmitter can be used to recall previously set memory positions. Transmitters are manufactured with an assigned personality number (1, 2, or 3) and are so designated on the back of the transmitter. The transmitter assigned with personality 1 is capable of recalling memory position 1 only. Similarly, the personality 2 and 3 transmitters can recall only memory positions 2 and 3 respectively. ^ Memory recall occurs when the UNLOCK switch is depressed on the transmitter. The second depression of the UNLOCK switch, which unlocks passenger doors, does not initiate a memory recall. ^ A memory recall in progress does not prohibit the initiation of another memory recall; the most recently requested memory recall will be executed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Moonroof Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 431 Sunroof / Moonroof Switch: Description and Operation When the roof sliding panel switch is rocked rearward, the sliding roof panel moves back into the storage space between the roof trim panel and the roof panel. The sliding roof panel can be moved to the fully closed position by rocking the roof sliding panel switch forward. When the sliding roof panel is in the fully closed position, the rear portion can be raised to provide ventilation by rocking the roof sliding panel switch forward. The sliding roof panel can be closed by rocking the roof sliding panel switch rearward. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 436 Brake Fluid Level Sensor/Switch: Description and Operation The brake fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) or secondary (rear) system will cause this system to activate. If the brake fluid level warning switch is inoperative, the brake master cylinder reservoir must be replaced. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations Differential Speed Sensor: Locations Body View The Differential Speed Sensor is located on the rear axle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications TORQUE SPECIFICATIONS Parking Brake Remote Release To Instrument Panel Bolts .............................................................................................................................................. 2.1-2.9 Nm (18.7-25.8 inch lbs.) Parking Brake Release Handle Screws ................................................................................................................................. 2.7-3.7 Nm (25-33 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front Anti-Lock Brake Sensor Bolt 63-80 in.lb Front ABS Sensor Wire Bracket Bolt 62-80 in.lb Rear Anti-Lock Brake Sensor Bolt 25-29 ft.lb Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring Wheel Speed Sensor: Service and Repair Toothed Ring Rear The rear sensor indicator is built into the rear differential. Refer to rear differential for disassembly and assembly procedures. Removal and Installation The front anti-lock brake sensor indicator is integral to the front wheel hub. If the indicator is bad, the wheel hub must be replaced. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 448 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Front REMOVAL 1. Disconnect the front anti-lock brake sensor electrical connector. 2. Remove the front disc brake rotor shield. 3. Remove the (A) two front anti-lock brake sensor bolts and the (B) front anti-lock brake sensor. INSTALLATION 1. To install, reverse the removal procedure. Rear REMOVAL 1. Remove the rear anti-lock brake sensor. 1 Disconnect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 449 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. NOTE: Remove all dirt from the mounting surface and sensor to prevent contamination of rear axle lubrication. INSTALLATION 1. Clean and inspect the rear anti-lock brake sensor. 1 Clean the axle mounting surface. 2 Inspect and clean the magnetized rear anti-lock brake sensor pole piece. 3 Inspect the rear anti-lock brake sensor O-ring for damage. Replace if necessary. 4 Lightly lubricate the rear anti-lock brake sensor O-ring with Synthetic SAE 75W-140 Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. CAUTION: Use care not to get dirt in the rear axle housing. 2. Install the rear anti-lock brake sensor. 1 Position the rear anti-lock brake sensor and install the rear anti-lock brake sensor bolt. NOTE: Do not apply force to the plastic rear anti-lock brake sensor connector. 2 Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor ............................................................................................................................... 16-24 Nm (11.8-17.4 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 455 Engine Views Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 456 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Remove the Engine Coolant Temperature sensor (ECT sensor). 1 Disconnect the electrical connector. 2 Remove the engine coolant temperature sensor. INSTALLATION 1. Install the engine coolant temperature sensor. 1 Install the engine coolant temperature sensor. 2 Connect the electrical connector. 2. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Description and Operation Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications Cylinder Head Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor ...................................................................................................................................... 19-25 Nm (14-18 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications > Page 463 Cylinder Head Temperature Sensor: Locations Engine View The Cylinder Head Temperature Sensor is located on the top front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications > Page 464 Cylinder Head Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the cylinder head temperature sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. Install the CHT sensor. 1 Install the sensor. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Service and Repair Temperature Sensor (Gauge): Service and Repair REMOVAL 1. Partially drain the engine cooling system. 2. Remove the water temperature indicator sender unit. 1 Disconnect the electrical connector. 2 Remove the water temperature indicator sender unit. INSTALLATION 1. Install the water temperature indicator sender unit. 1 Install the water temperature indicator sender unit. 2 Connect the electrical connector. 2. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 477 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 478 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 479 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 480 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 481 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 482 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 483 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 484 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 485 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 486 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 487 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 488 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 489 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 490 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 491 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 492 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 493 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 494 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 495 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 496 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 497 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 498 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 499 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 500 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 501 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 502 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 507 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 517 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 518 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 519 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 520 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 521 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 522 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 523 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 524 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 525 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 526 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 527 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 528 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 529 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 530 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 531 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 532 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 533 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 534 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 535 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 536 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 537 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 538 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 539 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 540 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 541 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 542 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 547 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 570 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 571 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 576 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 577 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 578 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 584 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 585 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 590 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 591 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 592 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 593 Cruise Control Switch: Service and Repair REMOVAL 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 (B) remove the speed control actuator switch. 2 Disconnect the speed control actuator switch electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC Air Door Position Sensor / Switch: Diagrams Air Door Position Sensor / Switch, HVAC Front Mode Potentiometer Rear Mode Potentiometer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC > Page 599 Air Door Position Sensor / Switch: Diagrams Blend Door Position Sensor Front Blend Potentiometer Rear Blend Potentiometer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation Ambient Temperature Sensor / Switch HVAC: Description and Operation The A/C ambient air temperature sensor and bracket: - is located in front of the A/C condenser core near the center of the vehicle. - contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the electronic automatic temperature control assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch Blower Motor Switch: Diagrams Blower Switch Front Blower Motor Switch Rear Blower Motor Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 607 Rear Integrated Control Panel (Rear Blower Switch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 608 Blower Motor Switch: Diagrams Blower Switch Illumination Front Blower Switch Illumination Rear Blower Switch Illumination Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch Blower Motor Switch: Testing and Inspection Blower Switch Blower Motor Switch - Component Testing Procedure Blower Motor Switch - Terminal Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 611 Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 612 Blower Motor Switch: Testing and Inspection Front Blower Switch Front Blower Motor Switch - Component Testing Procedure Front Blower Motor Switch - Terminal Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 613 Front Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 614 Blower Motor Switch: Testing and Inspection Rear Auxiliary Rear Blower Motor Switch - Component Testing Procedure Rear Blower Motor Switch - Terminal Locations Rear Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Specifications Cabin Temperature Sensor / Switch: Specifications In-Car Temperature Sensor Screws ...................................................................................................................................................... 2-3 Nm (18-27 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Specifications > Page 618 Cabin Temperature Sensor / Switch: Description and Operation The in-car temperature sensor operates in the following manner: - A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. - An automatic temperature control sensor hose and elbow is connected between the plenum assembly and the in-car temperature sensor. - The automatic temperature control sensor hose and elbow uses air from the plenum assembly air stream to create a suction at the in-car temperature sensor. - The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Specifications > Page 619 Cabin Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the center instrument panel finish panel. 1 Carefully pry to release the four clips. 2. Disconnect the control switch connector. 3. Remove the screws and the accessory outlet trim panel. 4. Remove the screws. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Specifications > Page 620 5. Disconnect the electrical connector and remove the sensor from the hose. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications A/C Cycling Switch .............................................................................................................................. .......................................... 1.4-3.8 Nm (12-33 Lb-In) Pressure Cut Off Switch ............................................................................................................................................................. 6.8-13.6 Nm (61-121 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 625 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Cycling Switch Closes .................................................................................................................. ......................................................... 324 kPa (47 psi) A/C Cycling Switch Opens ............................. .............................................................................................................................................. 152 kPa (22 psi) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch Typical Air Conditioning Pressure Sensor The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1724 kPa (250 psi) the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 628 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). - The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). - When the A/C cycling switch contacts close, the A/C clutch field coil is energized. - When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the A/C cycling pressure switch electrical connector. 2. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring seal with Motorcraft YN-12b refrigerant oil F2AZ-19577-AB or equivalent meeting Ford specification WSH-M1C231-B. 2. Perform refrigerant system Leak Detection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 631 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the electrical connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. Follow the removal procedure in reverse order. 1 Lubricate the O-ring seal with Motorcraft YN-12b refrigerant oil F2AZ-19577-AB or equivalent meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation Solar Sensor: Description and Operation The A/C sunload sensor: - is located on the top of the instrument panel. - contains a photovoltaic diode that is sensitive to light. - has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Page 635 Solar Sensor: Service and Repair REMOVAL 1. Remove the instrument panel upper finish panel. 2. Disconnect the connector. 3. Remove the A/C sunload sensor from the instrument panel upper finish panel. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations Dimmer Switch: Locations The panel dimmer switch is integrated into the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Page 640 Dimmer Switch: Description and Operation The panel dimmer switch is integrated into the headlamp switch and controls the interior lamps by activating the interior lamp relay. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Directional Sensor > Component Information > Locations Directional Sensor: Locations Body View The Compass Sensor is located in the overhead console. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Directional Sensor > Component Information > Locations > Page 644 Compass Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the electrical connector. 2 Rotate interior lamp switch counterclockwise to remove. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the (A) ignition switch lock cylinder release tab while pulling out the (B) ignition switch lock cylinder. 3. Remove the key in ignition warning switch. 1 Pry the clip downward. 2 Release the key-in-ignition warning switch from the rear of the ignition switch lock cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Service and Repair > Page 651 INSTALLATION 1. To install, reverse the removal procedure. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Transmission View The Digital Transmission Range Sensor is located at the left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 656 Backup Lamp Switch: Diagrams Digital Transmission Range Sensor Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 657 Backup Lamp Switch: Service and Repair The backup lamp switch is integral to the Digital Transmission Range (DTR)sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation Brake Light Switch: Description and Operation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 661 The Brake Pedal Position (BPP) switch controls the brake lamps and rear hi-mount lamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 662 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Brake Pedal Position (BPP) switch electrical connector. 3. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the (A) BPP switch from the (B) brake master cylinder push rod. 3 Remove the brake master cylinder push rod spacer. 4 Remove the brake master cylinder push rod bushing. INSTALLATION 1. To install, reverse the removal procedure. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement Technical Service Bulletin # 99B02 Date: 990301 Campaign - Multifunction Switch Replacement 99B02 OWNER NOTIFICATION PROGRAM Certain 1997-98 Expedition and 1998 Navigator Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ All Dealer Letter: Lincoln Commitment Special Handling Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 671 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 672 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles that are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS PREPARATION See Sections 5 & 6 of the ACESII manual for detailed instructions. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code 99B02 Misc. Expense REFUND Misc. Expense ADMIN. Misc. Expense 0.2 Hr. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 673 LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channel as noted. DEALER PRICE For latest prices, check or call your: -- Order Processing Center -- DOES II -- Updated Price Book EXCESS STOCK RETURN Excess stock return for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION -- Enter using DWE -- Use code information shown below: Program Code - 99B02 Labor Operation - See Above See Sections 5 & 6 of the ACESII manual for detailed instructions. To claim for the "Lincoln Commitment Special Handling", follow the instructions in Attachment IV. Attachment III - Technical Information TECHNICAL INSTRUCTIONS Please refer to Service Manual procedures: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 674 ^ Group 2: Chassis ^ Section 211-05: Steering Column Switches ^ Removal and Installation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 675 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 676 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 677 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement Technical Service Bulletin # 99B02 Date: 990301 Campaign - Multifunction Switch Replacement 99B02 OWNER NOTIFICATION PROGRAM Certain 1997-98 Expedition and 1998 Navigator Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ All Dealer Letter: Lincoln Commitment Special Handling Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 683 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 684 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles that are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS PREPARATION See Sections 5 & 6 of the ACESII manual for detailed instructions. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code 99B02 Misc. Expense REFUND Misc. Expense ADMIN. Misc. Expense 0.2 Hr. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 685 LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channel as noted. DEALER PRICE For latest prices, check or call your: -- Order Processing Center -- DOES II -- Updated Price Book EXCESS STOCK RETURN Excess stock return for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION -- Enter using DWE -- Use code information shown below: Program Code - 99B02 Labor Operation - See Above See Sections 5 & 6 of the ACESII manual for detailed instructions. To claim for the "Lincoln Commitment Special Handling", follow the instructions in Attachment IV. Attachment III - Technical Information TECHNICAL INSTRUCTIONS Please refer to Service Manual procedures: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 686 ^ Group 2: Chassis ^ Section 211-05: Steering Column Switches ^ Removal and Installation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 687 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 688 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 689 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the electrical connector. 2 Rotate interior lamp switch counterclockwise to remove. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation Fog/Driving Lamp Switch: Description and Operation The headlamp switch is a four position switch that controls the headlamps, exterior lamps, panel lamps, and, if equipped, the fog lamps and autolamp system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Page 696 Fog/Driving Lamp Switch: Service and Repair The fog lamp switch is integral to the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Multi_function Switch Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 700 Hazard Warning Switch: Description and Operation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 701 The multi-function switch controls the turn signals, high beams, and hazard lamps. The Brake Pedal Position (BPP) switch controls the brake lamps and rear hi-mount lamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis Hazard Warning Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 704 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 705 Hazard Warning Switch: Pinpoint Tests A1 - A2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 706 A3 - A4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 707 B1 - B2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 708 C1 D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 709 Hazard Warning Switch: Component Tests and General Diagnostics Multi-Function Switch Component Test Multi-Function Switch - Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 710 Multi-Function Switch - Terminals Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 711 Multi-Function Switch - schematic - Dimmer,Flash To Pass,Turn/Hazard Portion Of Multi-Function Switch Multi-Function Switch Electrical Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 712 1. Measure the resistance between the multi-function switch terminals. 2. If the resistances are as specified, multi-function switch is OK. RETURN the multi-function switch to the vehicle. TEST the system for normal operation. If the resistances are not as specified. REPLACE the multi-function switch. TEST the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 716 Headlamp Dimmer Switch: Diagrams Multi_function Switch Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 717 Headlamp Dimmer Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. The integrated multi-function switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer, rear wiper/washer and hazard warning. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Headlamp Dimmer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 720 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 721 Headlamp Dimmer Switch: Pinpoint Tests A1 - A2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 722 A3 - A4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 723 B1 - B2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 724 C1 D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 725 Headlamp Dimmer Switch: Component Tests and General Diagnostics Multi-Function Switch Component Test Multi-Function Switch - Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 726 Multi-Function Switch - Terminals Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 727 Multi-Function Switch - schematic - Dimmer,Flash To Pass,Turn/Hazard Portion Of Multi-Function Switch Multi-Function Switch Electrical Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 728 1. Measure the resistance between the multi-function switch terminals. 2. If the resistances are as specified, multi-function switch is OK. RETURN the multi-function switch to the vehicle. TEST the system for normal operation. If the resistances are not as specified. REPLACE the multi-function switch. TEST the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 729 Headlamp Dimmer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Release the four clips and remove the steering column opening cover. NOTE: Move gear selector to lowest position to access steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 730 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Main Light Switch (C244) Main Light Switch (C245) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 734 Main Light Switch (C246) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 735 Headlamp Switch: Description and Operation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 736 The headlamp switch is a four position switch that controls the headlamps, exterior lamps, panel lamps, and, if equipped, the fog lamps and autolamp system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 737 Headlamp Switch: Testing and Inspection Main Light Switch -Component Testing Procedure (Part 1 Of 2) Main Light Switch - Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 738 Main Light Switch - Terminal Location Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 739 Main Light Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Autolamp Time Delay Switch Headlamp Switch: Service and Repair Autolamp Time Delay Switch The autolamp time delay switch is integral to the headlamp switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Autolamp Time Delay Switch > Page 742 Headlamp Switch: Service and Repair Headlamp Switch REMOVAL 1. Disconnect the battery ground cable. 2. Turn the headlamp switch knob to the headlamp position and pull the knob. 3. Insert a thin tool to release the headlamp switch knob and remove. 4. Turn the headlamp switch knob 180 degrees and install. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Autolamp Time Delay Switch > Page 743 5. Turn counterclockwise until the back of the headlamp switch knob is in the OFF position. 6. Turn the headlamp switch knob fully clockwise. 7. Remove the headlamp switch. 1 Pull the headlamp switch from the instrument panel. 2 Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Testing and Inspection Horn Switch: Testing and Inspection The horn switch is integral to the driver side air bag module. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the electrical connector. 2 Rotate interior lamp switch counterclockwise to remove. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 753 Turn Signal Switch: Diagrams Multi_function Switch Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 754 Turn Signal Switch: Description and Operation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 755 The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. The integrated multi-function switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer, rear wiper/washer and hazard warning. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis Turn Signal Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 758 Turn Signal Switch: Diagnostic Trouble Code Descriptions Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 759 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 760 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 761 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 762 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 763 Turn Signal Switch: Component Tests and General Diagnostics Multi-Function Switch Electrical Test 1. Measure the resistance between the multi-function switch terminals. 2. If the resistances are as specified, multi-function switch is OK. RETURN the multi-function switch to the vehicle. TEST the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 764 If the resistances are not as specified. REPLACE the multi-function switch. TEST the system for normal operation. Multi-Function Switch Component Test Multi-Function Switch - Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 765 Multi-Function Switch - Terminals Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 766 Multi-Function Switch - schematic - Dimmer,Flash To Pass,Turn/Hazard Portion Of Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 767 Turn Signal Switch: Pinout Values and Diagnostic Parameters Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 768 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 769 Turn Signal Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Release the four clips and remove the steering column opening cover. NOTE: Move gear selector to lowest position to access steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 770 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 781 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 782 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 788 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 789 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 790 Air Flow Meter/Sensor: Specifications Mass Air Flow Sensor Plate Nuts .................................................................................................................................................. 8-11.5 Nm (5.9-8.5 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 791 Air Flow Meter/Sensor: Locations Engine View The Mass Air Flow Sensor is located in the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 792 Air Flow Meter/Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Open the engine air cleaner. - Disconnect the MAF sensor extension harness connector from the wiring harness. - Release the air cleaner clamp. - Separate the inlet side of the engine Air Cleaner (ACL) from the outlet side of the engine air cleaner. CAUTION: Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. 3. Cut the tape on the wire loom of the extension harness. - Peel back the wire loom from the extension harness near the grommet in the engine air cleaner. 4. Remove the grommet from the outlet side of the engine air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 793 5. Remove the MAF sensor plate and Mass Air Flow sensor (MAF sensor) from the outlet side of the engine engine air cleaner. 6. Disconnect the MAF sensor electrical connector from the extension harness. 7. Separate the MAF sensor plate from the mass air flow sensor. - Remove the nuts from the MAF sensor plate. INSTALLATION CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation There is no actual Barometric Pressure Sensor on this vehicle. The Mass Air Flow Sensor calculates a value for the barometric pressure and sends this information to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt ......................................................................................................................................................... 8-12 Nm (71-106 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 800 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located in front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 801 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 4.6L shown, 5.4L similar 2. Remove the Camshaft Position sensor (CMP sensor). 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor ............................................................................................................................... 16-24 Nm (11.8-17.4 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 805 Engine Views Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 806 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Remove the Engine Coolant Temperature sensor (ECT sensor). 1 Disconnect the electrical connector. 2 Remove the engine coolant temperature sensor. INSTALLATION 1. Install the engine coolant temperature sensor. 1 Install the engine coolant temperature sensor. 2 Connect the electrical connector. 2. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Engine View The Crankshaft Position Sensor is located at the lower front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 810 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the accessory drive belt. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Disconnect the Crankshaft Position (CKP) electrical connector. 4. Disconnect the A/C compressor. 1 Remove the bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the (CKP) sensor bolt and the crankshaft position sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 811 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications Cylinder Head Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor ...................................................................................................................................... 19-25 Nm (14-18 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications > Page 815 Cylinder Head Temperature Sensor: Locations Engine View The Cylinder Head Temperature Sensor is located on the top front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications > Page 816 Cylinder Head Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the cylinder head temperature sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. Install the CHT sensor. 1 Install the sensor. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Engine View The Intake Air Temperature Sensor is located on the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 820 Intake Air Temperature Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls. 1. Disconnect the battery ground cable. 2. Disconnect the IAT sensor electrical connector. 3. Remove the Intake Air Temperature sensor (IAT sensor). INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor (KS) .............................................................................................................................. ............................................. 15-20 Nm (11-15 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 824 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Knock Sensor (KS). 1 Disconnect the electrical connector. 2 Remove the knock sensor. INSTALLATION 1. Install the knock sensor. 1 Install the knock sensor. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Oxygen Sensor: Customer Interest PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 833 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 834 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 835 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 841 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 842 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 843 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 844 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 845 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 846 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 847 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 848 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 849 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 850 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 851 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 852 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 853 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 854 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 855 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Oxygen Sensor: All Technical Service Bulletins PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 860 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 861 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 862 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 868 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 869 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 870 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 871 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 872 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 873 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 874 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 875 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 876 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 877 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 878 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 879 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 880 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 881 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 882 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 883 Oxygen Sensor: Specifications Heated Oxygen Sensor (Front or Rear) ............................................................................................................................................ 36-46 Nm (26-34 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 886 Exhaust System Component Location - 4.6L Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 889 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 890 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 891 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 892 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 893 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 894 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 895 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 896 Oxygen Sensor: Connector Views Ford does not provide connector views for this vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Front Oxygen Sensor: Service and Repair Front Oxygen Sensor Wrench REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Disconnect the two HO2S electrical connectors. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Use the Oxygen Sensor Wrench to remove the Heated Oxygen Sensors (HO2S). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Front > Page 899 INSTALLATION 1. Install and tighten the heated oxygen sensors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Front > Page 900 Oxygen Sensor: Service and Repair Rear Oxygen Sensor Wrench REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Remove the rear Heated Oxygen Sensor (HO2S). 1 Disconnect the electrical connectors. 2 Use the Oxygen Sensor Wrench to remove the heated oxygen sensors. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications EGR Transducer Nuts ......................................................................................................................... ........................................... 2.2-5.5 Nm (22-49 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 904 Pressure Feedback Exhaust Sensor: Locations Engine View The Differential Pressure Feedback EGR Sensor is located at the right side of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 905 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the EGR transducer. 1 Remove the EGR transducer hoses. 2 Disconnect the EGR transducer electrical connector. 3 Remove the nuts. 4 Remove the EGR transducer. 4.6L engine is shown; 5.4L engine is similar INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position (TP) Sensor Bolts ............................................................................................................................................... 2.8-3.4 Nm (25-30 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 909 Throttle Position Sensor: Locations Engine View The Throttle Position Sensor is attached to the throttle body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 910 Throttle Position Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the splash shield. 3. Remove the Throttle Position sensor (TP sensor). 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the throttle position sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 911 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS Transmission Range (TR) Sensor Bolts .................................................................................................................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 915 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at the left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 916 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 917 Transmission Position Switch/Sensor: Description and Operation DIGITAL TRANSMISSION RANGE (TR) SENSOR The Digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in Park and Neutral, the back-up lamp circuit in Reverse and the neutral sense circuit (4x4 only) in Neutral. The digital TR sensor also opens and closes a set of four switches that are monitored by the powertrain control module to determine the position of the manual lever (P,R,N,D,2,1). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 918 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Disconnect the digital TR electrical connector. 6. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 7. Loosen the digital TR bolts. 8. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 919 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. 9. Tighten the bolts. 10. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 11. With the manual lever in overdrive connect the shift lever control cable. 12. Install the digital TR sensor electrical connector. 13. Lower the vehicle. 14. Connect the battery ground cable. 15. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications TORQUE SPECIFICATIONS Vehicle Speed Sensor (VSS) Bolt ........................................................................................................................................ 11-13 Nm (98-115 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 923 Vehicle Speed Sensor: Locations Transmission View The Vehicle Speed Sensor is located at the left rear of transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 926 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 927 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 928 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 929 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 930 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 931 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 932 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 933 Vehicle Speed Sensor: Service and Repair REMOVAL 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise and support the vehicle. 4. Remove the Vehicle Speed Sensor (VSS). 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the VSS. 5. Remove the Vehicle Speed Sensor (VSS) drive gear. 1 Remove the retaining clip. 2 Remove the driven gear. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 934 1. Install Vehicle Speed Sensor (VSS) drive gear. 1 Install the driven gear. 2 Install the retaining clip. 2. Install the VSS. 1 Install the VSS. 2 Install the bolt. 3 Connect the electrical connector. 3. Lower the vehicle. 4. Connect the battery ground cable. 5. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications EGR Transducer Nuts ......................................................................................................................... ........................................... 2.2-5.5 Nm (22-49 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 939 Pressure Feedback Exhaust Sensor: Locations Engine View The Differential Pressure Feedback EGR Sensor is located at the right side of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 940 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the EGR transducer. 1 Remove the EGR transducer hoses. 2 Disconnect the EGR transducer electrical connector. 3 Remove the nuts. 4 Remove the EGR transducer. 4.6L engine is shown; 5.4L engine is similar INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 950 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 951 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 957 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 958 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Technical Service Bulletins > Page 959 Air Flow Meter/Sensor: Specifications Mass Air Flow Sensor Plate Nuts .................................................................................................................................................. 8-11.5 Nm (5.9-8.5 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Technical Service Bulletins > Page 960 Air Flow Meter/Sensor: Locations Engine View The Mass Air Flow Sensor is located in the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Technical Service Bulletins > Page 961 Air Flow Meter/Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Open the engine air cleaner. - Disconnect the MAF sensor extension harness connector from the wiring harness. - Release the air cleaner clamp. - Separate the inlet side of the engine Air Cleaner (ACL) from the outlet side of the engine air cleaner. CAUTION: Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. 3. Cut the tape on the wire loom of the extension harness. - Peel back the wire loom from the extension harness near the grommet in the engine air cleaner. 4. Remove the grommet from the outlet side of the engine air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Technical Service Bulletins > Page 962 5. Remove the MAF sensor plate and Mass Air Flow sensor (MAF sensor) from the outlet side of the engine engine air cleaner. 6. Disconnect the MAF sensor electrical connector from the extension harness. 7. Separate the MAF sensor plate from the mass air flow sensor. - Remove the nuts from the MAF sensor plate. INSTALLATION CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications Inertia Fuel Shutoff Switch: Specifications Inertia Fuel Shutoff Switch Bolts ................................................................................................................................................... 1.6-2.2 Nm (15-19 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 966 Inertia Fuel Shutoff Switch: Locations The inertia fuel shutoff switch is located in the right kick panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 967 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. The IFS 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 968 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the RH cowl side trim panel. 3. Disconnect the inertia fuel shutoff switch electrical connector. 4. Remove the inertia fuel shutoff switch. 1 Remove the bolts. 2 Remove the inertia fuel shutoff switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position (TP) Sensor Bolts ............................................................................................................................................... 2.8-3.4 Nm (25-30 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 972 Throttle Position Sensor: Locations Engine View The Throttle Position Sensor is attached to the throttle body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 973 Throttle Position Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the splash shield. 3. Remove the Throttle Position sensor (TP sensor). 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the throttle position sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 974 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt ......................................................................................................................................................... 8-12 Nm (71-106 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 979 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located in front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 980 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 4.6L shown, 5.4L similar 2. Remove the Camshaft Position sensor (CMP sensor). 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Engine View The Crankshaft Position Sensor is located at the lower front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 984 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the accessory drive belt. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Disconnect the Crankshaft Position (CKP) electrical connector. 4. Disconnect the A/C compressor. 1 Remove the bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the (CKP) sensor bolt and the crankshaft position sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 985 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 991 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 992 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 993 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 994 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 995 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 996 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Functional Ignition Switch Lock Cylinder: Service and Repair Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key and turn to the RUN position. (2) Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Functional > Page 999 Ignition Switch Lock Cylinder: Service and Repair Non-Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Functional > Page 1000 - Thoroughly clean all drill shavings from the steering column and inspect for damage. INSTALLATION 1. To install, reverse the removal procedure, using a new ignition switch lock cylinder. - Verify ignition switch lock cylinder operation. NOTE: - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. - Use a new ignition switch lock cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor (KS) .............................................................................................................................. ............................................. 15-20 Nm (11-15 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 1004 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Knock Sensor (KS). 1 Disconnect the electrical connector. 2 Remove the knock sensor. INSTALLATION 1. Install the knock sensor. 1 Install the knock sensor. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Air Bag Sensor Screws .......................................................................................................................................................... 10.2-13.8 N.m (90-122 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Primary Crash Sensor Impact Sensor: Locations Left Front Primary Crash Sensor Engine View The Left Primary Crash Sensor is located at the left front of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Primary Crash Sensor > Page 1011 Impact Sensor: Locations Right Primary Crash Sensor Engine View The Right Primary Crash Sensor is located at the right front of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1012 Impact Sensor: Description and Operation WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION WHERE THE RADIATOR GRILLE OPENING PANEL, FRAME RAILS, OR COWL PANELS HAVE BEEN DAMAGED, INSPECT THE SENSOR MOUNTING BRACKETS FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAGS ARE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE SENSOR MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. NOTE: Undamaged air bag sensors will reset automatically after a collision and can be reused. The air bag Supplemental Restraint System (SRS) contains the following three sensors. ^ LH air bag sensor and bracket. ^ RH air bag sensor and bracket. ^ Safing sensor that is internal to the air bag diagnostic monitor. At least two sensors (one air bag sensor and the safing sensor) must be closed to inflate the air bag. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1013 Impact Sensor: Service and Repair 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. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. NOTE: A repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable. 2. Remove the radiator air deflector. 1. Remove the push clips. 2. Remove the radiator air deflector 3. Disconnect the air bag sensor electrical connector (RH shown, LH similar). 4. Remove the air bag sensor. 1. Remove the screws. 2. Remove the air bag sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1014 INSTALLATION WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED. NOTE: A repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Follow the removal procedure in reverse order. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Description and Operation Safing Sensor: Description and Operation WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION WHERE THE RADIATOR GRILLE OPENING PANEL, FRAME RAILS, OR COWL PANELS HAVE BEEN DAMAGED, INSPECT THE SENSOR MOUNTING BRACKETS FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAGS ARE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE SENSOR MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. NOTE: Undamaged air bag sensors will reset automatically after a collision and can be reused. The air bag Supplemental Restraint System (SRS) contains the following three sensors. ^ LH air bag sensor and bracket. ^ RH air bag sensor and bracket. ^ Safing sensor that is internal to the air bag diagnostic monitor. At least two sensors (one air bag sensor and the safing sensor) must be closed to inflate the air bag. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1024 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1025 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1026 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1027 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1028 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 1029 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key and turn to the RUN position. (2) Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 1032 Ignition Switch Lock Cylinder: Service and Repair Non-Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 1033 - Thoroughly clean all drill shavings from the steering column and inspect for damage. INSTALLATION 1. To install, reverse the removal procedure, using a new ignition switch lock cylinder. - Verify ignition switch lock cylinder operation. NOTE: - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. - Use a new ignition switch lock cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Transmission View The Digital Transmission Range Sensor is located at the left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1037 Neutral Safety Switch: Diagrams Digital Transmission Range Sensor Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Description and Operation Steering Angle Sensor: Description and Operation The steering sensor is mounted inside the passenger compartment on the steering column. It provides steering rate and position to the control module through two signals. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Description and Operation > Page 1043 Steering Angle Sensor: Service and Repair REMOVAL 1. Remove the steering column. 2. Remove the shock absorber electronic steering sensor. (1) Disconnect the electrical connector. (2) Remove the screws. (3) Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. (1) Remove the steering column lower bearing spring. (2) Remove the sensor ring. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Description and Operation > Page 1044 2. Install the shock absorber electronic steering sensor. (1) Position the shock absorber electronic steering sensor. (2) Install the screws. (3) Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Electrical Specifications Ride Height Sensor: Electrical Specifications GENERAL SPECIFICATIONS Rear Height Sensor Voltage ................................................................................................................ .................................................... 2.66 ± 0.02 volts Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Electrical Specifications > Page 1050 Ride Height Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Ball Stud Nut ........................................................................................................................................ .......................... 10.2-13.8 Nm (91-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front Ride Height Sensor: Locations Front Body View The Front Height Sensor is located behind the left running board. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front > Page 1053 Ride Height Sensor: Locations Rear Body View The Rear Height Sensor is located under left rear of vehicle near the axle housing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 1054 Ride Height Sensor: Description and Operation Two height sensors are mounted on the vehicle. The sensors send a voltage signal to the control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce), to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensors have a useable range of 80 mm (3 in) compared to total suspension travel of 200-250 mm (8-10 in) at the wheel. Therefore, the sensors are mounted to the suspension at a point where full suspension travel at the wheel is relative to 80 mm (3 in) of travel at the height sensor. The front height sensor upper socket is attached to the bracket to the frame at the upper control arm mounting area and the lower height sensor socket is attached to the upper control arm bracket. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace a sensor as a unit. When the height sensor indicates that the vehicle is lower than trim under normal driving conditions, the air compressor will turn on and pump compressed air to the system. When the sensor indicates that the vehicle is raised above trim under normal driving conditions, this will cause the air to be vented from the system to lower the vehicle to its trim height level. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 1055 Ride Height Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Remove the air suspension height sensor. (1) Disconnect the electrical connector. (2) Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. NOTE: - Rear height sensor shown; front similar. - The air suspension has a plastic harness retainer that must be unclipped prior to removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Description and Operation Steering Angle Sensor: Description and Operation The steering sensor is mounted inside the passenger compartment on the steering column. It provides steering rate and position to the control module through two signals. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Description and Operation > Page 1059 Steering Angle Sensor: Service and Repair REMOVAL 1. Remove the steering column. 2. Remove the shock absorber electronic steering sensor. (1) Disconnect the electrical connector. (2) Remove the screws. (3) Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. (1) Remove the steering column lower bearing spring. (2) Remove the sensor ring. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Description and Operation > Page 1060 2. Install the shock absorber electronic steering sensor. (1) Position the shock absorber electronic steering sensor. (2) Install the screws. (3) Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications TORQUE SPECIFICATIONS Bracket Mounting Bolt ................................................................................................................................................... 10.2-13.8 Nm (92-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 1064 Suspension Mode Switch: Locations The air suspension switch is located behind the RH kick panel on a mounting bracket. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 1065 Suspension Mode Switch: Description and Operation The air suspension switch is located behind the RH kick panel on a mounting bracket. The switch interrupts power to the control module. The air suspension switch supplies a signal to the control module. Without the control module receiving this signal the load leveling system is inoperative and will not react when rear of the vehicle is raised or lowered. If the air suspension is disabled by turning off air suspension switch, a "CHECK SUSP" will appear in the RH corner of the cluster with the ignition in the run position. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 1066 Suspension Mode Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 1067 5. Remove the air suspension switch bracket mounting bolt. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission > Page 1074 Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Page 1075 Overdrive Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) AND TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The Transmission Control Switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the Transmission Control Indicator Lamp (TCIL) when the switch is off. The TCIL indicates overdrive cancel mode activated (lamp on) and Electronic Pressure Control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Overdrive Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the transmission external control. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart: 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1078 Overdrive Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1079 Overdrive Switch: Pinpoint Tests Test C1 - C2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1080 Test C2 - C3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1081 Test C3 - C4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1082 Test C4 - C5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Page 1083 Overdrive Switch: Service and Repair REMOVAL 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS Transmission Range (TR) Sensor Bolts .................................................................................................................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 1087 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at the left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 1088 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 1089 Transmission Position Switch/Sensor: Description and Operation DIGITAL TRANSMISSION RANGE (TR) SENSOR The Digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in Park and Neutral, the back-up lamp circuit in Reverse and the neutral sense circuit (4x4 only) in Neutral. The digital TR sensor also opens and closes a set of four switches that are monitored by the powertrain control module to determine the position of the manual lever (P,R,N,D,2,1). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 1090 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Disconnect the digital TR electrical connector. 6. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 7. Loosen the digital TR bolts. 8. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 1091 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. 9. Tighten the bolts. 10. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 11. With the manual lever in overdrive connect the shift lever control cable. 12. Install the digital TR sensor electrical connector. 13. Lower the vehicle. 14. Connect the battery ground cable. 15. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Transmission Speed Sensor: Locations Transmission View The Output Shaft Speed Sensor is located at the left side of the transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Page 1095 Output Shaft Speed Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Page 1096 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED (OSS) SENSOR The Output Shaft Speed (OSS) sensor is a magnetic pickup, located at the output shaft ring gear, that sends a signal to the Powertrain Control Module (PCM) to indicate transmission output shaft speed. The OSS is used for torque converter clutch control, shift scheduling and to determine electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Temperature Sensor, Transmission Control Transmission Temperature Sensor/Switch: Description and Operation Temperature Sensor, Transmission Control TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR The Transmission Fluid Temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermister. It sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits Torque Converter Clutch (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Temperature Sensor, Transmission Control > Page 1101 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor/Switch, A/T TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR The Transmission Fluid Temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermister. It sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits Torque Converter Clutch (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications Gear Sensor/Switch: Specifications TORQUE SPECIFICATIONS Shift Range Selector Switch Screws ........................................................................................................................................... 2-3 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications > Page 1109 Gear Sensor/Switch: Service and Repair REMOVAL 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the shift range selector switch knob. 2 Disconnect the shift range selector switch electrical connector. 3 Remove the two shift range selector switch bolts. 4 Remove the shift range selector switch. INSTALLATION 1. Install the shift range selector switch. 1 Position the shift range selector switch. 2 Install the bolts. 3 Install the electrical connector. 4 Install the knob. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications > Page 1110 2. Install the center instrument panel trim panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Speed Sensor Bolt ........................................................................................................................................................... 3-6 Nm (27-53 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Rear Heated Window Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 1118 Heated Glass Element Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Pry carefully to release the clips and remove the steering column opening cover. NOTE: Position the gear shifter into low or drive 1 position. 3. Remove the headlamp switch. 4. Remove the instrument panel finish panel. 1 Remove the panel bolts. 2 Remove the instrument panel finish panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 1119 5. Disconnect the electrical connector. 6. Remove the heated backlight switch. ^ Remove the screws. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Power Window Control Switch Power Window Switch: Locations Power Window Control Switch The window regulator control switch is located on each door trim panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Power Window Control Switch > Page 1124 Power Window Switch: Locations Rear Quarter Glass Regulator Control Switches The rear quarter glass regulator control switches are located in the overhead console. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch Power Window Switch: Diagrams Power Window Switch Left Front Power Window Switch (C510) Left Front Power Window Switch (C509) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 1127 Right Front Power Window Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 1128 Power Window Switch: Diagrams Rear Power Window Switch Left Rear Window Switch Right Rear Window Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 1129 Power Window Switch: Diagrams Vent Window Switch Left Rear Vent Window Switch Right Rear Vent Window Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Rear Quarter Glass Regulator Control Switches Power Window Switch: Description and Operation Rear Quarter Glass Regulator Control Switches The rear quarter glass regulator control switches: - Are located in the overhead console. - May be used to open and close the RH or LH rear quarter windows. - Stop the rear quarter glass in any position when released. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Rear Quarter Glass Regulator Control Switches > Page 1132 Power Window Switch: Description and Operation Window Regulator Control Switch The window regulator control switch: - Is located on each door trim panel. - May be used to raise or lower all windows from the master control on the driver side, or the individual side window from the individual door switch. - Includes a "double detent" feature. - Can manually lower the driver side window when the master control is depressed half way (first detent). - Will completely lower the driver side window when the master control is fully depressed and then released (second detent). - Can lock out passenger front and rear control switches. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1137 Windshield Washer Switch: Diagrams Multi_function Switch Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1138 Windshield Washer Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. The integrated multi-function switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer, rear wiper/washer and hazard warning. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Windshield Washer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1141 Windshield Washer Switch: Diagnostic Trouble Code Descriptions GEM Diagnostic Trouble Code Index Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1142 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1143 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1144 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1145 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1146 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1147 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1148 Windshield Washer Switch: Component Tests and General Diagnostics Multi-Function Switch Component Test Multi-Function Switch - Component Testing Procedure Multi-Function Switch - Terminals Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1149 Multi-Function Switch - Schematic - Wiper/Washer Portion Of Multi-Function Switch Multi-Function Switch Electrical Test 1. Measure the resistance between the multi-function switch terminals. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1150 2. If the resistances are as specified, multi-function switch is OK. RETURN the multi-function switch to the vehicle. TEST the system for normal operation. If the resistances are not as specified. REPLACE the multi-function switch. TEST the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1151 Windshield Washer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Release the four clips and remove the steering column opening cover. NOTE: Move gear selector to lowest position to access steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1152 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1156 Wiper Switch: Diagrams Multi_function Switch Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1157 Wiper Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. The integrated multi-function switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer, rear wiper/washer and hazard warning. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1160 Wiper Switch: Pinpoint Tests A1 - A2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1161 A3 - A4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1162 B1 - B2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1163 C1 D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1164 Wiper Switch: Component Tests and General Diagnostics Multi-Function Switch Component Test Multi-Function Switch - Component Testing Procedure Multi-Function Switch - Terminals Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1165 Multi-Function Switch - Schematic - Wiper/Washer Portion Of Multi-Function Switch Multi-Function Switch Electrical Test 1. Measure the resistance between the multi-function switch terminals. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1166 2. If the resistances are as specified, multi-function switch is OK. RETURN the multi-function switch to the vehicle. TEST the system for normal operation. If the resistances are not as specified. REPLACE the multi-function switch. TEST the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1167 Wiper Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Release the four clips and remove the steering column opening cover. NOTE: Move gear selector to lowest position to access steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1168 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1174 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1175 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1176 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1177 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1178 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1179 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1180 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1181 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1182 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1183 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1184 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1185 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1186 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1187 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1188 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1189 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1190 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1191 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1192 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1193 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1194 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1195 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1196 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1197 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1198 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1199 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1200 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1201 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1202 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1203 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1204 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1205 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1206 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1207 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1208 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1209 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1210 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1211 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1212 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1213 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1214 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1215 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1216 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1217 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1218 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1219 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1220 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1221 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1222 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1223 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1224 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1225 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1226 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1227 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1228 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1229 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1230 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1231 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1232 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1233 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1234 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1235 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1236 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1237 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1238 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1239 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1240 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1241 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1242 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1243 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1244 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1245 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1246 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1247 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford 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Comprehensive Noise/Vibration/Harshness Procedure > Page 1252 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1253 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1254 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1255 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1256 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1257 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1258 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1259 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1260 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1261 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1262 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1263 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1264 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1265 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1266 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 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. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1267 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 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. 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 the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1268 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1269 Alignment: Technical Service Bulletins Alignment - Toe Setting Procedure Tip Article No. 98-16-9 08/17/98 STEERING - ALIGNMENT - TOE SET PROCEDURE - SERVICE TIP LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250, NAVIGATOR ISSUE It may be difficult to set toe with the jam nut tie rod sleeve while performing an alignment on some vehicles. This may be caused by the toe adjusting sleeve moving when the opposing jam nut is torqued. ACTION Refer to the following Service Procedure to ensure complete and accurate toe set/alignment by preventing the jam nut from backing off during the toe set procedure. SERVICE PROCEDURE When adjusting toe on 1997-98 F-150/F-250, Expedition, or Navigator, follow this procedure on each side of the vehicle when tightening the jam nuts. 1. Set toe to specification. 2. Make sure the inner and outer ball joint sockets are centered perpendicular to their studs. 3. Prevent the adjuster sleeve from rotating by securing it with a tool (pipe wrench or vise grip) against the lower control arm. 4. Torque one (1) jam nut to 90 Nm (66 lb-ft). 5. Paint a line across the adjuster sleeve and the torqued jam nut and another line across the torqued jam nut and tie rod threads. 6. With the wrench still preventing the adjuster sleeve from rotating, torque the other jam nut to 90 Nm (66 lb-ft). 7. Inspect the paint lines to be sure no relative movement of the adjuster sleeve, jam nut, or tie rod occurred. 8. If movement is detected or toe is no longer within specification, loosen both jam nuts, reset toe if necessary, and repeat procedure. 9. Repeat procedure for other side of vehicle. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 303000, 390000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1270 Alignment: Specifications BASE SUSPENSION ALIGNMENT Caster LH ........................................................................................................................................................ ....................................................... 5.1° ± 1.0° RH ............................................................................. .................................................................................................................................. 5.6° ± 1.0° Total/Split ............................................................................................................................................. ..................................................... -0.5° ± 0.7° Camber LH ........................................................................................................................................................ ...................................................... -0.2° ± 0.7° RH ............................................................................. ................................................................................................................................ -0.2° ± 0.7° Total/Split ............................................................................................................................................. ...................................................... 0.0° ± 0.7° Toe LH ........................................................................................................................................................ ................................................................ 0.15° RH ............................................................................. .......................................................................................................................................... 0.15° Total/Split ............................................................................................................................................. ................................................. -0.30° ± 0.25° AIR SUSPENSION ALIGNMENT (TRIM POSITION) Caster LH ........................................................................................................................................................ ....................................................... 5.0° ± 1.0° RH ............................................................................. .................................................................................................................................. 5.5° ± 1.0° Total/Split ............................................................................................................................................. ..................................................... -0.5° ± 0.7° Camber LH ........................................................................................................................................................ ...................................................... -0.4° ± 0.4° RH ............................................................................. ................................................................................................................................ -0.4° ± 0.4° Total/Split ............................................................................................................................................. ...................................................... 0.0° ± 0.7° Toe LH ........................................................................................................................................................ ................................................................ 0.10° RH ............................................................................. .......................................................................................................................................... 0.10° Total/Split ............................................................................................................................................. ................................................. -0.20° ± 0.25° RIDE HEIGHT Rear Curb Ride Height: Without Air Suspension .................................................................................................................................................... 218-242 mm (8.6-9.5 inch) With Air Suspension ......................................................................................................................................................... 168-178 mm (6.6-7.0 inch) Vehicle Lean Specifications Max. Allowable Variance, Front ...................................................................................................................................................... 16 mm (5/8 inch) Max. Allowable Variance, Rear ....................................................................................................................................................... 19 mm (3/4 inch) Ride Height Measurement Original Components Base Suspension ............................................................................................................................................................ 102-132 mm (4.02-5.20 inch) Air Suspension Ignition Off (Kneel Position) ................................................................................................................... 60-87 mm (2.36-3.42 inch) Ride Height, Original Components Base Suspension ............................................................................................................................................................ 107-113 mm (4.21-4.44 inch) Air Suspension Ignition Off (Kneel Position) ..................................................................................................................... 76-82 mm (3.0-3.23 inch) Ride Height, New Components Base Suspension ............................................................................................................................................................ 122-128 mm (4.80-5.04 inch) Air Suspension Ignition Off (Kneel Position) ..................................................................................................................... 76-82 mm (3.0-3.23 inch) Rear Vehicle Height [a] ................................................................................................................................................. 144.8-148.8 mm (5.7-5.8 inches) [a] From Bottom Of Frame To Rear Jounce Bumper Bolt Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1271 Alignment: Locations Wheel Alignment Adjusting Locations, Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1272 Alignment: Description and Operation Wheel Alignment Adjusting Locations, Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1273 DESCRIPTION Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting bolts. Toe is adjusted by the use of the front wheel spindle tie rod adjusting sleeve. The three basic alignment angles are camber, caster and toe. Camber and toe affect tire wear and directional stability, caster affects directional stability only. Camber, caster and toe settings change when the vehicle is loaded. The specifications given are static settings with the vehicle unloaded. CAMBER Camber is the inward or outward tilting of the wheels at the top. When the wheels tilt out at the top the camber is positive (+). When the wheels tilt in at the top the camber is negative (-). The amount of camber is measured in degrees from vertical. Steering axis inclination (included angle) is the center line drawn through the ball joints when viewed from the front. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1274 CASTER Caster is the tilting of the steering axis either forward or backward from vertical. A backward tilt is positive (+) and a forward tilt is negative (-). TOE Toe is a measurement of how much the front of the wheels are turned in or out from the straight-ahead position. When the wheels are turned in, toe is positive (+)(toe in). When the wheels are turned out, toe is negative (-)(toe out). Toe is measured in degrees, from side to side and totaled. Toe should only be checked and adjusted after the camber and caster have been set to the proper specifications. Wheel Track Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1275 WHEEL TRACK By design the vehicle has a front track that is wider at the front than the rear. Front track is the distance between the two front tires; rear track is the distance between the two rear tires. Dogtracking DOGTRACKING Dogtracking is the condition where the rear axle is not square to the chassis. Heavily crowned roads may give the illusion of dogtracking. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber Alignment: Service and Repair Caster and Camber 1. Loosen the upper suspension arm nuts to a point where the joints are snug. 2. To increase caster and camber, use the following steps. (1) To increase caster, move the front of the front suspension upper arm outboard and move the rear of the front suspension upper arm inboard. (2) To increase camber, move the front suspension upper arm outboard equally. NOTE: A pry bar can be used between the front suspension upper arm and the frame pocket to aid in moving the arm. 3. To decrease caster and camber, use the following steps. (1) To decrease caster, move the front of the front suspension upper arm inboard and move the rear of the front suspension upper arm outboard. (2) To decrease camber, move the front suspension on upper arm inboard equally. 4. Set the caster and camber to specifications. - If a caster increase of 0.9 degree is required, move the front of the front suspension upper arm outboard by 3 notches and move the rear of the front suspension upper arm inboard by 3 notches. NOTE: Each increment of the notches on the frame pocket represents 0.3 degree. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber > Page 1278 5. Tighten the upper suspension arm nuts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber > Page 1279 Alignment: Service and Repair 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 by attaching, a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings; follow manufacturer's instructions. 4. Hold the tie rod end while loosening the toe set jam nuts. 5. Rotate the front wheel spindle tie rod adjusting sleeve to desired position. 6. Tighten the toe set jam nuts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber > Page 1280 NOTE: Whenever the toe set jam nuts are loosened for toe adjustment, the nut and tie rod threads must be cleaned and lubricated. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve .................................................................................................................. .................................................. 7.75 Nm (68.6 Lb/In) Fuel Pressure Relief Valve Cap ..................... ........................................................................................................................................... 0.6 Nm (5.3 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 1286 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE 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. 1. Perform the fuel pressure release procedure. 2. Remove the (A) fuel pressure relief valve with the (B) fuel pressure relief valve cap. INSTALLATION 1. Install fuel pressure relief valve. 2. Install the fuel pressure relief valve cap. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 680 - 830 RPM Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet engine Air Cleaner (ACL) aside. 2. Remove the (A) air cleaner element from the (B) open end of the inlet engine air cleaner. INSTALLATION 1. Install the air cleaner element. 2. Position the engine air cleaner aligning the alignment tab. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet engine air cleaner has an alignment tab which fits into a slot on the outlet engine air cleaner. This ensures a good seal and keeps unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1294 3. Close the air cleaner clamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 EFI/CFI Fuel Pressure Gauge WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place the fuel in a suitable container. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 1302 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 1303 Firing Order 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order Firing Order: 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair REMOVAL CAUTION: Spark plug wires must be connected to the proper ignition coil terminal and spark plug. Mark the spark plug wire locations. 1. Grasp the spark plug boot firmly and use a twisting, pulling motion to disconnect the spark plug wires from the spark plugs. 2. Squeeze the locking tabs and disconnect the spark plug wire from the ignition coil. INSTALLATION 1. Apply Silicone Brake Caliper Grease Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire boots. 2. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark Plug Torque ............................................................................................................................... ............................................. 9-20 Nm (80-178 Lb/In) Spark Plug Gap ............................................... ....................................................................................................................... 1.32-1.42 mm (0.052-0.056 in) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 1315 Spark Plug: Specifications Torque Spark Plug Torque ............................................................................................................................... ............................................. 9-20 Nm (80-178 Lb/In) Spark Plug Gap ............................................... ....................................................................................................................... 1.32-1.42 mm (0.052-0.056 in) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1316 Spark Plug: Application and ID RH Original Spark Plug ....................................................................................................................... ........................................................ AWSF32PG (a) LH Original Spark Plug ..................................... ............................................................................................................................................. AWSF32P (a) Replacement Spark Plug (Either Side) ......................................................................................................................................................... AWSF32PP (a) (a) If a spark plug is removed for examination, it must be reinstalled in the same cylinder. If a new spark plug needs to be installed, use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1317 Spark Plug: Service and Repair REMOVAL CAUTION: Spark plug wires must be connected to the proper ignition coil terminal and spark plug. Mark the spark plug wire locations. NOTE: Use compressed air to remove any debris from the spark plug well before removing the spark plugs. 1. Grasp the spark plug boot firmly and use a twisting, pulling motion to disconnect the spark plug wires from the spark plugs. 2. Remove the spark plugs. NOTE: Remove any foreign debris from the spark plug wells with compressed air. 3. Inspect the spark plug. INSTALLATION 1. Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire boots. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1318 2. Adjust the spark plug gap as required. 3. Install the spark plugs. 4. Connect the spark plug wires. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test Compression Check: Testing and Inspection Compression Test 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as Compression Tester in No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, use the auxiliary starter switch to 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test > Page 1324 Compression Check: Testing and Inspection Interpreting Compression Readings 1. If compression improves considerably, the piston rings require service. 2. If compression does not improve, the valves are sticking or seating improperly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on the piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil and/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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test > Page 1325 Compression Check: Testing and Inspection Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Use the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil SAE 1OW-40XO-1OW40-QSP meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer does not indicate whether this vehicle has adjustable or non-adjustable valves. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation Drive Belt: Description and Operation The accessory drive consists of the: drive belt. ^ generator pulley. ^ power steering pump pulley. ^ crankshaft pulley. ^ A/C clutch pulley. ^ belt idler pulley. ^ drive belt tensioner. ^ water pump pulley. The accessory drive: ^ has a single serpentine drive belt. ^ has an automatic drive belt tensioner. ^ does not require adjustment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 1. Verify customer concern by running the engine. 2. Inspect the drive belt for chunking, fraying and wear. 3. Check the drive belt for correct routing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1334 Drive Belt: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1335 Drive Belt: Component Tests and General Diagnostics Belt Tension NOTE: Drive belt tension is not adjustable. The drive belt tensioner automatically adjusts drive belt tension. Check the automatic drive belt tensioner: 1. With the engine off, check for proper drive belt routing. 2. Rotate the drive belt tensioner and check for a binding or frozen condition. Replace components as required. Cracking/Chunking/Wear V-Ribbed Belt With Cracks (Acceptable) Vee Ribbed Serpentine Drive Belt With Cracks Across Backing V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) Vee Ribbed Belt With Chunks of Rib Missing Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. Non-standard replacement drive belts may track differently or improperly. If a replacement drive belt tracks improperly, replace it with an original equipment drive belt to avoid performance failure or loss of drive belt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1336 With the engine running, check drive belt tracking. If the (A) edge of the drive belt rides beyond the edge of the pulleys, noise and premature wear may occur. Make sure the (B) drive belt rides correctly on the pulley. If a drive belt tracking condition exists, proceed with the following: Visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. This will result in chirp and squeal noises. ^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Replace components as required. ^ Check all accessories, mounting brackets and the drive belt tensioner for any interference that would prevent the component from mounting properly. Correct any interference condition and recheck the drive belt tracking. ^ Tighten all accessories, mounting brackets, and drive belt tensioner retaining hardware to specification. Recheck the drive belt tracking. Drive Belt Noise/Flutter NOTE: Tensioner is shown in free-state position against arm travel stops. Part 1 Of 2 Part 2 Of 2 Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged pulley or an improperly aligned pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley, look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain conditions, such as: engine start up, rapid Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1337 engine acceleration, or A/C clutch engagement. Drive belt squeal can occur under certain conditions: ^ If the A/C discharge pressure goes above specifications: the A/C system is overcharged. - the A/C condenser core airflow is blocked. ^ If the A/C OFF equalized pressure (the common discharge and suction pressure that occurs after several minutes) exceeds specifications. ^ If any of the accessories are damaged, have a worn or damaged bearing, internal torsional resistance above normal. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. ^ If fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive belt with soap and water and thoroughly rinse with clean water. The drive belt does not have to be replaced if no apparent damage has occurred. ^ If the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the drive belt tensioner indicator is outside the installation wear range window, replace the drive belt. NOTE: The drive belt tensioner arm should rotate freely without binding. ^ If the drive belt tensioner is worn or damaged. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1338 Drive Belt: Service and Repair REMOVAL 1. Use (B) 1/2 inch square hole in drive belt tensioner pulley hub to rotate (A) drive belt tensioner clockwise and remove the (C) drive belt. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet engine Air Cleaner (ACL) aside. 2. Remove the (A) air cleaner element from the (B) open end of the inlet engine air cleaner. INSTALLATION 1. Install the air cleaner element. 2. Position the engine air cleaner aligning the alignment tab. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet engine air cleaner has an alignment tab which fits into a slot on the outlet engine air cleaner. This ensures a good seal and keeps unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1344 3. Close the air cleaner clamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair Note: Not all of these vehicles were equipped with a Cabin Air Filter. Only vehicles with a filter cover in the location shown have a Cabin Air Filter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair REMOVAL 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Place a drain pan under the transmission fluid pan. 5. Drain transmission fluid. - Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 6. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. 7. Pull down evenly and remove the transmission fluid filter, seal and filter kit. 8. Remove torque converter housing plug. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1351 9. Remove the torque converter drain plug and drain the torque converter. - Rotate the crankshaft to access the drain plug. 10. Clean and inspect the (A) transmission fluid pan, (B) transmission fluid pan gasket and (C) magnet. 11. Flush the fluid cooler and fluid cooler lines. 12. Flush the torque converter. INSTALLATION 1. NOTE: A new torque converter drain plug must be used. Install the torque converter drain plug. 2. Install torque converter housing plug. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1352 3. 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 serviced for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. 5. 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 transmission fluid pan gasket. 2 Position the transmission fluid pan. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1353 6. Install bolts. 7. Lower the vehicle. 8. Connect the battery ground cable. 9. If equipped with air suspension, reactivate the system by turning on the air suspension switch. 10. NOTE: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). Fill transmission to proper fluid level. Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON(R) V. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair EFI/CFI Fuel Pressure Gauge WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place the fuel in a suitable container. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1362 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1363 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1364 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 (V8-281 4.6L SOHC (1998)) 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 1374 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 (V8-281 4.6L SOHC (1998)) 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 1375 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 (V8-281 4.6L SOHC (1998)) 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 (V8-281 4.6L SOHC (1998)) 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 1381 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 (V8-281 4.6L SOHC (1998)) 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 1382 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1383 Heater Hose: Specifications Hose Clamp ......................................................................................................................................... ........................................... 1.6-2.2 Nm (17-22 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line Heater Hose: Service and Repair Front Auxiliary Heater Outlet and Inlet Line REMOVAL NOTE: The front auxiliary heater outlet line is shown; the front auxiliary heater inlet line is similar. 1. Drain the cooling system. 2. Turn the air suspension switch off, if equipped. 3. Raise and support the vehicle. 4. Remove the RH front fender splash shield. 1 Remove the bolts. 2 Remove the pushpins. 3 Remove the front fender splash shield. 5. Remove the four line brackets. 1 Remove the nuts. 2 Remove the bracket by inserting a screwdriver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 6. Disconnect the heater outlet line from the outlet hose coupling. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1386 7. Disconnect the front auxiliary heater outlet line from the rear auxiliary heater outlet line. 1 Remove the nut. 2 Disconnect the line. 8. Cut the heater outlet line in the locations shown. 9. Remove and discard the cut sections. INSTALLATION 1. Install the heater outlet line. - Install the end with the blue tape over the frame. 2. Install the heater outlet line. - Install the end with the red tape over the frame. - Install the end with the yellow tape between the frame and the body vertical flange. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1387 3. Connect the two heater water outlet lines. 1 Connect the fitting. 2 Loosely install the nut. 4. Install the heater water outlet line. - Install the line through the wheel opening. 5. Connect the two heater water outlet lines. 1 Connect the fitting. 2 Loosely install the nut. 6. Tighten the two peanut fittings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1388 7. Install the line brackets. 1 Position the bracket. 2 Install the nut. - Snap the line into the bracket. CAUTION: Verify that clearance exists between the frame and the lines to prevent component damage. NOTE: The bracket must be positioned equally between the white location marks on the line. 8. Connect the heater water outlet line to the engine heater outlet hose coupling. 9. Install the bolts, the pushpins and the front fender splash shield. 10. Lower the vehicle. 11. Turn on the air suspension switch, if equipped. 12. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1389 Heater Hose: Service and Repair Heater Hose Couplings Heater Hose Disconnect Tool SPECIAL TOOL(S) DISCONNECT 1. Depressurize the engine cooling system. WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. Push the Heater Hose Disconnect Tool over the coupling retainer windows to compress the retainer locking tabs. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Tool must be perpendicular to and on the highest point of the coupling. 4. Pull the heater water hose away from the heater core tube. NOTE: A slight twisting motion while pulling on the heater waster hose may be necessary to assist in the removal. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1390 7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer. CONNECT 1. Clean the tubes and lubricate with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESR-M99B112-A. 2. Install a new coupling retainer, spacer, and lubricated O-rings into the quick disconnect coupling housing. 3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the coupling is fully engaged by lightly pulling on the heater water hose. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1391 Heater Hose: Service and Repair Rear Auxiliary Heater Inlet Line REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater inlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1392 9. Remove the four line brackets. 1 Remove the nuts. 2 Remove the bracket by inserting a screwdriver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 10. Cut the line in the positions shown. 11. Remove and discard the cut sections. INSTALLATION 1. Install the heater inlet line. - Install the end with the green tape over the axle between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1393 2. Connect the heater inlet line to the front auxiliary line. 1 Connect the inlet line. 2 Loosely install the nut. 3. Install the heater inlet line. - Install the end with the blue tape between the frame crossmember and the floor pan. 4. Connect the two heater inlet lines. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater inlet line. - Install the end with the red tape between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1394 6. Connect the two heater inlet lines. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater inlet line. - Install the end with the green tape through the floor opening. 8. Connect the two heater inlet lines. 1 Connect the fittings. 2 Loosely install the nut. 9. Tighten the four peanut fittings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1395 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. - Snap the line into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the line. 11. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1396 15. Connect the heater inlet hose coupling. 16. Install the quarter trim access panel. 17. Install the spare tire. 18. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1397 Heater Hose: Service and Repair Rear Auxiliary Heater Outlet Line REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater outlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1398 9. Remove the four line brackets. 1 Remove the nuts. 2 Remove the bracket by inserting a screwdriver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 10. Cut the line in the positions shown. 11. Remove and discard the cut sections. INSTALLATION 1. Install the heater outlet line. - Install the end with the blue tape over the axle between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1399 2. Connect the heater outlet line to the front auxiliary line. 1 Connect the fittings. 2 Loosely install the nut. 3. Install the heater outlet line. - Install the end with the red tape between the frame and the crossmember. 4. Connect the two heater outlet lines. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater outlet line. - Install the end with blue tape between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1400 6. Connect the heater outlet line to the heater outlet line. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater outlet line. - Install the end with the hose through the floor opening. 8. Tighten the four peanut fittings. 9. Install the line brackets. 1 Position the bracket. 2 Install the nut. - Snap the line into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1401 10. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 11. Lower the vehicle. 12. Turn on the air suspension switch, if equipped. 13. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 14. Connect the heater outlet hose coupling. 15. Install the quarter trim access panel. 16. Install the spare tire. 17. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1402 Heater Hose: Service and Repair Removal and Installation REMOVAL 1. Drain the radiator. 2. Disconnect the heater outlet hose at the engine. 3. Disconnect the heater inlet hose at the engine. 1 Loosen the hose clamp. 2 Disconnect the heater inlet hose. 4. Compress the holding tabs and disconnect the heater water hoses at the heater core. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1403 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Page 1404 Heater Hose Disconnect Tool Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications A/C Evaporator to Expansion Valve Lines ..................................................................................................... 12.7-17.3 Nm (10-12 Lb-Ft) (113-154 Lb-In) A/C Line Bracket Nuts ............................................................................................... .................................................................... 6.8-9.2 Nm (61-82 Lb-In) Outline Line to Auxiliary Evaporator Case Line ............................................................................................................................ 6.8-9.2 Nm (61-82 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Refrigerant Lines Hose/Line HVAC: Description and Operation Refrigerant Lines NOTE: Whenever a refrigerant line is replaced, it is also necessary to replace the suction accumulator/drier. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the following features: - the upstream side contains low pressure refrigerant gas. - the downstream side contains high pressure refrigerant gas. - an integral non-serviceable muffler and a serviceable high pressure A/C charge port valve are located on the downstream side. - the downstream side also contains a fitting used to mount the A/C pressure cut-off switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cut-off switch can be removed without discharging the A/C system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Refrigerant Lines > Page 1410 Hose/Line HVAC: Description and Operation Underbody A/C-Heater Lines Item Description 1 Green Tape 2 Front Auxiliary Heater Inlet Line 3 Blue Tape 4 Front Auxiliary Heater Inlet Line 5 White Tape (Bracket Locations) 6 Orange Tape 7 Front Auxiliary Heater Inlet Line 8 Rear Auxiliary Heater Outlet Line 9 Rear Auxiliary Evaporator Outlet Line 10 Rear Auxiliary Heater Inlet Line 11 Violet Tape 12 Rear Auxiliary Evaporator Outlet Line Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Refrigerant Lines > Page 1411 13 Front Auxiliary Heater Outlet Line 14 Red Tape 15 Rear Auxiliary Heater Inlet Line 16 Rear Auxiliary Heater Outlet Line 17 Rear Auxiliary Evaporator Outlet Line 18 Rear Auxiliary Evaporator Inlet Line 19 Yellow Tape 20 Rear Auxiliary Evaporator Inlet Line 21 Rear Auxiliary Evaporator Outlet Line 22 Rear Auxiliary Evaporator Outlet Line 23 Rear Auxiliary Evaporator Inlet Line 24 Rear Auxiliary Evaporator Inlet Line 25 Rear Auxiliary Heater Outlet Line 26 Rear Auxiliary Heater Inlet Line 27 Rear Auxiliary Heater Inlet Line 28 Rear Auxiliary Heater Outlet Line 29 Front Auxiliary Heater Outlet Line 30 Front Auxiliary Heater Outlet Line The auxiliary lines are one-piece tubes that are secured to the underbody of the vehicle. Replacement kits are only available with multiple-piece lines for ease of installation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil Hose/Line HVAC: Service and Repair Adding Refrigerant Oil 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 for replacement, 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 replacement part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. 1 Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 1414 4. For the A/C condenser core, add 30 ml (1 ounce) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when performing each of the following repairs: replacement of the A/C evaporator core orifice - replacement of the A/C compressor pressure relief valve - replacement of a refrigerant line - repair of an O-ring leak - repair of a charge port leak 6. Replacement of components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 1415 Hose/Line HVAC: Service and Repair Condenser To Evaporator Line REMOVAL 1. Disconnect the battery ground cable. 2. Recover the refrigerant. 3. Disconnect the condenser to evaporator line spring lock coupling from the A/C evaporator core. 4. Disconnect the A/C condenser core lower line. 1 Remove the nut. 2 Disconnect the A/C condenser core lower line. 5. Remove the tube bracket nut. 6. Remove the suction accumulator/drier bracket clamp bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 1416 7. Remove the evaporator to condenser tube. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring seal with Motorcraft YN-12b refrigerant oil F2AZ-19577-AB or equivalent meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 1417 Hose/Line HVAC: Service and Repair Front Auxiliary Evaporator Outlet and Inlet Line REMOVAL NOTE: The front auxiliary evaporator outlet line is shown, the front auxiliary evaporator inlet line is similar. 1. Recover the refrigerant from the system. 2. Turn the air suspension switch off, if equipped. 3. Raise and support the vehicle. 4. Remove the RH front fender splash shield. 1 Remove the bolts. 2 Remove the pushpins. 3 Remove the front fender splash shield. 5. Remove the three line brackets. 1 Remove the nuts. 2 Remove the bracket by inserting a screwdriver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 6. Disconnect the auxiliary outlet line from the condenser line. 1 Remove the nut. 2 Disconnect the line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 1418 7. Disconnect the front auxiliary outlet line from the rear auxiliary line. 1 Remove the nut. 2 Disconnect the line. 8. Remove the front auxiliary evaporator outlet line. INSTALLATION 1. Install the front auxiliary evaporator outlet line. 2. Connect the front auxiliary outlet line to the rear auxiliary line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 1419 3. Connect the front auxiliary outlet line to the condenser line. 1 Connect the line. 2 Install the nut. 4. Install the line brackets. 1 Position the bracket. 2 Install the nut. - Snap the line into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the line. 5. Install the front fender splash shield. 6. Lower the vehicle. 7. Turn on the air suspension switch, if equipped. 8. Evacuate and charge the A/C system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 1420 Hose/Line HVAC: Service and Repair Rear Auxiliary Evaporator Inlet Line REMOVAL 1. Discharge and recover the refrigerant. 2. Remove the quarter trim panel access cover. 3. Disconnect the inlet line from the underbody line. 1 Remove the nut. 2 Remove the line. 4. Remove the auxiliary A/C lines grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Remove the four line brackets. 1 Remove the nuts. 2 Remove the bracket by inserting a screwdriver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 1421 9. Disconnect the inlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. 10. Cut the (3/8 inch) inlet line in four places. 11. Remove and discard the cut sections. INSTALLATION 1. Install the inlet line from the rear of the vehicle over the frame. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 1422 2. Connect the inlet line to the front underbody A/C lines. 1 Connect the inlet line. 2 Loosely install the nut. 3. Install the inlet line over the frame. - Insert the end with the orange tape first. 4. Connect the two inlet lines. 1 Connect the inlet lines. 2 Loosely install the nut. 5. Install the inlet line. - Install the end with the yellow tape between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 1423 6. Connect the two inlet lines. - Connect the fitting and loosely install the nut. 7. Install the inlet line. - Install the end without tape through the floor. 8. Connect the inlet line to the inlet line. 1 Connect the line. 2 Loosely install the nut. 9. Tighten the four peanut fittings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 1424 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. - Snap the line into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the line. 11. Lower the vehicle. 12. Turn on the air suspension switch, if equipped. 13. Connect the inlet line to the auxiliary evaporator case line. 14. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Install the quarter trim access panel. 16. Evacuate and charge the A/C system. 17. Install the spare tire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 1425 Hose/Line HVAC: Service and Repair Rear Auxiliary Evaporator Outlet Line REMOVAL 1. Discharge and recover the refrigerant. 2. Remove the quarter trim panel access cover. 3. Disconnect the outlet line from the underbody line. 1 Remove the nut. 2 Remove the line. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Remove the four line brackets. 1 Remove the nuts. 2 Remove the bracket by inserting a screwdriver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 1426 9. Disconnect the outlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. 10. Cut the outlet line in four places. 11. Remove and discard the cut sections. INSTALLATION 1. Install the outlet line over the frame. - Install the end with violet tape between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 1427 2. Connect the outlet line peanut fitting. 1 Connect the outlet lines. 2 Loosely install the nut. 3. Install the outlet line. - Install the end with the violet tape between the frame and body. 4. Connect the outlet line peanut fitting to the outlet line. 1 Connect the outlet lines. 2 Loosely install the nut. 5. Install the outlet line. - Install the end with the yellow tape over the frame. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 1428 6. Connect the outlet line peanut fitting to the outlet line. - Connect the fitting and loosely install the nut. 7. Install the outlet line. - Install the end with the orange tape between the frame and the body near the rear wheel opening. 8. Connect the outlet line peanut fitting to the outlet line. - Connect the fitting and loosely install the nut. 9. Install the outlet line. - Install the end of the tube with no tape through the floor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 1429 10. Connect the outlet line peanut fitting to outlet line. - Connect the fitting and loosely install the nut. 11. Tighten the five peanut fittings. 12. Install the line brackets. 1 Position the bracket. 2 Install the nut. - Snap the line into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the line. 13. Lower the vehicle. 14. Turn the air suspension switch on, if equipped. 15. Connect the outlet line to the auxiliary evaporator case line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 1430 16. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 17. Install the quarter trim access panel. 18. Evacuate and charge the A/C system. 19. Install the spare tire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Page 1431 Hose/Line HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications TORQUE SPECIFICATIONS Power Steering Pressure Hose Fitting ........................................................................................................................................ 17-23 Nm (13-17 ft. lbs.) Power Steering Return Hose Fitting ........................................................................................................................................... 17-23 Nm (13-17 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose Power Steering Line/Hose: Service and Repair Low Pressure Hose REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the power steering low pressure hose. Drain the power steering system. 3. Lower the vehicle. 4. Disconnect and remove the power steering low pressure hose. INSTALLATION 1. Follow the removal procedure in reverse order 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 1437 Power Steering Line/Hose: Service and Repair Pressure Hose REMOVAL 1. Prepare the vehicle for power steering pressure hose removal. (1) Remove the fan and shroud. (2) Remove the drive belt. 2. Disconnect the power steering pressure hose. Drain the power steering system. 3. Remove the power steering pump pulley using the Power Steering Pump Pulley Remover 4. Disconnect and remove the power steering pressure hose. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 1438 1. Install a new seal on the power steering pressure hose at the power steering pump end. - Remove and discard the original seal. - Stretch the seal over the Seal Replacer until it is large enough to slip over the tube nut. 2. Route the power steering pressure hose in the vehicle. Connect the power steering pressure hose. 3. Install the power steering pump pulley. - Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks, replace the pulley. If there is no paint or one paint mark, use a paint pencil to mark the web area of the pulley near the hub. - Use the Power Steering Pump Pulley Replacer. CAUTION: Replacement of the power steering pump pulley is necessary after being removed and installed two times. 4. Connect the power steering pressure hose. 5. Restore the vehicle to operating condition. (1) install the drive belt. (2) Install the fan and shroud. (3) Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 1439 Power Steering Line/Hose: Service and Repair Pump Reservoir Hose REMOVAL 1. Prepare the vehicle for power steering reservoir pump hose removal. (1) Remove the fan and shroud. (2) Remove the drive belt. 2. Remove the three bolts. 3. Disconnect the power steering reservoir pump hose. Drain the power steering system. 4. Remove the nuts and belt deflector 5. Remove the two bolts. 6. Raise and support the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 1440 WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 7. Disconnect the Electronic Variable Orifice (EVO) power steering control valve actuator electrical connector. 8. Remove the bolt. 9. Lower the vehicle. 10. Position the power steering pump forward. 11. Disconnect and remove the power steering reservoir pump hose. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 1441 1. Route the power steering reservoir pump hose in the vehicle. Connect the power steering reservoir pump hose. 2. Position the power steering pump. 3. Loosely install the bolts. 4. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 5. Install the bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 1442 6. Connect the EVO power steering control valve actuator electrical connector. 7. Lower the vehicle. 8. Tighten the bolts. 9. Install the belt deflector and nuts. 10. Connect the power steering reservoir pump hose. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 1443 11. Position the power steering pump reservoir. Install the three bolts. 12. Restore the vehicle to operating condition. (1) Install the drive belt. (2) Install the fan and shroud. (3) Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 1444 Power Steering Line/Hose: Service and Repair Return REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the power steering return hose. Drain the power steering system. 3. Lower the vehicle. 4. Disconnect and remove the power steering return hose. INSTALLATION 1. Follow the removal procedure In reverse order 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Page 1445 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) Radiator Hose: Service and Repair Radiator Hoses (Lower) REMOVAL 1. Drain the engine cooling system. 2. Remove inlet side of engine Air Cleaner (ACL). 3. Disconnect the lower radiator hose from the oil filter adapter. 4. Disconnect the lower radiator hose from the degas bottle. 5. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 6. If equipped with engine oil cooler, disconnect the lower radiator hose connections from the oil cooler. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 1450 7. Disconnect the lower radiator hose from the radiator. 1 Pry the locking tab up and out of the slot. 2 Rotate the lower radiator hose. 3 Disconnect and remove the lower radiator hose. INSTALLATION 1. Follow the removal procedure in reverse order. NOTE: ^ If equipped with air suspension, reactivate the system by turning on the air suspension switch. ^ The lower radiator hose does not require rotation for installation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 1451 Radiator Hose: Service and Repair Radiator Hoses (Upper) REMOVAL 1. Partially drain the engine cooling system. 2. Remove the upper radiator hose. 1 Release the hose clamps and slide away from the hose ends. 2 Remove the upper radiator hose. INSTALLATION 1. Install the upper radiator hose. 1 Position the upper radiator hose. 2 Compress and position the hose clamps. NOTE: Make sure that the upper radiator hose is seated in the upper hose support bracket. 2. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. High Performance DOT3 Brake Fluid Ford Specification ESA-M6C25-A Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement Technical Service Bulletin # 98B33 Date: 990401 Campaign - Coolant/Cylinder Head Replacement OWNER NOTIFICATION PROGRAM 98B33 Certain 1997 and 1998 Expedition, F-150 and 1998 Navigator vehicles equipped with 4.6L and 5.4L engines for inspection of coolant and, if necessary, replacement of engine cylinder heads ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Requirements ^ Attachment IIIA ^ A - Coolant Test Instructions ^ Attachment IIIB ^ B - Cylinder Head Replacement Instructions ^ Attachment IV ^ Copy of Lincoln Commitment Special Handling Procedure Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1464 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1465 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles on the enclosed list. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1466 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with this special handling procedure. CLAIMS Enter claims using DWE. See ACESII Manual. To claim for the "Lincoln Commitment Special Handling", follow the instructions on Attachment IV. OWNER REFUNDS See ACESII Manual, Section 3 for submission procedures. For owner-paid repairs of cracked cylinder heads or damage directly related to cracked cylinder heads made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from servicing dealer), enter using DWE: RENTAL CARS If cylinder head replacement is necessary, Ford will pay for a loaner or rental vehicle except for fuel and insurance which will be at the owner's expense. Do not provide a rental vehicle while cylinder heads are on order. Rentals should be provided only while the vehicle is at the dealership for cylinder head replacement. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days vehicle was used in the Miscellaneous Expense area of the recall claim. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1467 COOLANT TESTER Coolant concentrate test kits will be sent at no charge 10 dealers with affected vehicles. Additional stock of testers is limited, but testers may be ordered from the Recall Hotline 1-800-325-5621. PARTS REQUIREMENTS Parts Ordering Information Cylinder head kits can be ordered by calling the Recall Hotline at 1-800-325-5621. The kits listed contain all parts necessary for cylinder head replacement except coolant, oil and oil filter: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1468 DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 98B33 ^ Labor Operation: (see Labor Allowances) See the ACESII manual for detailed instructions. Attachment IIIA - A-Coolant Test Instructions SERVICE PROCEDURE 1. Open hood. 2. Remove coolant recovery bottle cap. 3. Run engine until normal operating temperature (thermostat open) is reached. 4. Insert supplied glycol tester (Thexton 106) into coolant recovery bottle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1469 5. Fill tester to level shown in Figure 1. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1470 ^ If five (5) or less discs float, refer to Figure 2, no service action is needed. Return vehicle to customer. ^ If all six (6) discs float, indicating "NOT SAFE" glycol condition, see Figure 2, call Recall Hotline at 1-800-325-5621 to order cylinder head kit. Perform cylinder head replacement, when kit arrives. Removal Removal 1. On air suspension equipped vehicles, turn air suspension switch, located in the RH kick panel area, to the OFF position. 2. Install memory saver, then disconnect battery negative cable. 3. Remove shield covering throttle body assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1471 4. Disconnect mass air flow (MAF) sensor electrical connector. Refer to Figure 1. 5. Disconnect intake air temperature (IAT) sensor electrical connector. Refer to Figure 1. 6. Remove air cleaner half and clean air tube as an assembly. See Figure 1. 7. Remove remaining half of air cleaner. 8. Disconnect accelerator cable, speed control cable and return spring from throttle body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1472 9. Remove accelerator cable bracket from intake manifold, then unclip cables from clip on power steering reservoir bracket. See Figure 2. Position cable assembly aside. 10. On 4.6L engines, proceed as follows: ^ Disconnect vapor management valve (VMV) vacuum line at rear of throttle body adapter. Refer to Figure 3. ^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 3. ^ Disconnect PCV hose at rear of throttle body adapter. Refer to Figure 3. ^ Remove brake booster vacuum line retainer at EGR valve. Disconnect vacuum line at throttle body adapter. See Figure 3. Position line aside. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1473 ^ Disconnect vapor management valve (VMV) vacuum line. Refer to Figure 4. ^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 4. ^ Disconnect EGR valve vacuum line. Refer to Figure 4. ^ Disconnect EVR solenoid vacuum line. See Figure 4. ^ Position vacuum harness away from engine. 11. On 5.4L engines, proceed as follows: ^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 5. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1474 ^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle. 12. Raise vehicle. 13. Disconnect EGR tube from exhaust manifold. 14. Disconnect oil pressure switch electrical connector. See Figure 6. 15. Disconnect crankshaft position (CKP) sensor electrical connector. See Figure 7. 16. On 4X2 models, disconnect A/C clutch electrical connector. 17. Drain coolant from radiator. NOTE: Do not remove right side cylinder block coolant drain plug. 18. Remove left side cylinder block coolant drain plug. Allow coolant to completely drain. 19. Install cylinder block coolant drain plug. Tighten plug to 16-24 Nm (12-17 lb-ft). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1475 20. Drain engine oil. Do not final tighten drain plug at this time, as it will be removed again. 21. Lower vehicle. NOTE: The best access to the A/C electrical connector is through the wheel well. 22. On 4X4 models, disconnect A/C clutch electrical connector. 23. Mark and disconnect DPFE transducer hoses from EGR tube. 24. Disconnect EGR tube from EGR valve, then remove EGR tube from vehicle. 25. On 4.6L engines, proceed as follows: ^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 8. ^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1476 ^ Disconnect EVR solenoid electrical connector. Refer to Figure 9. ^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 9. ^ Disconnect Idle Air Control (IAC) motor electrical connector. Refer to Figure 9. ^ Disconnect DPFE transducer electrical connector. See Figure 9. ^ Disconnect left side coil pack electrical connector. Refer to Figure 10. ^ Disconnect camshaft position (CMP) sensor electrical connector. Refer to Figure 10. ^ Disconnect left side radio interference suppressor electrical connector. See Figure 10. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1477 ^ Disconnect ignition wires from left side coil pack. ^ Remove left side coil pack from vehicle. ^ Unclip left side fuel charge harness from cam cover studs. Refer to Figure 11. ^ Unclip ignition wire separators from left cam cover studs. See Figure 11. ^ Disconnect ignition wires from left side spark plugs. Route ignition wires to front of engine. ^ Disconnect left side fuel injector electrical connectors. 26. On 5.4L engines, proceed as follows: ^ Disconnect Vapor Management Valve (VMV) vacuum line. Refer to Figure 12. ^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 12. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1478 ^ Disconnect EGR valve vacuum line. Refer to Figure 12. ^ Disconnect EVR solenoid vacuum line. See Figure 12 ^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 13. ^ Position vacuum harness away from engine. ^ Disconnect VMV purge line at top of throttle body adapter. See Figure 13. ^ Disconnect brake booster vacuum line from throttle body adapter. ^ Remove brake booster vacuum line bracket from intake manifold. Position vacuum line assembly away from intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1479 ^ Disconnect Idle Air Control (IAC) motor electrical connector. See Figure 14. ^ Disconnect left side radio interference suppressor electrical connector. Refer to Figure 15. ^ Disconnect DPFE transducer electrical connector. Refer to Figure 15. ^ Disconnect EVR solenoid electrical connector. Refer to Figure 15. ^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 15. ^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1480 ^ Disconnect camshaft position (CMP) sensor electrical connector. See Figure 16. ^ Disconnect ignition coil electrical connectors from left side of engine. Refer to Figure 17. ^ Disconnect fuel injector electrical connectors from left side of engine. See Figure 17. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1481 ^ Remove left side fuel charge harness from cam cover studs, then position harness away from cam cover. See Figure 18. ^ Remove left side ignition coils from vehicle. WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 27. Relieve fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on EFI/CFI fuel pressure gauge. ^ Remove fuel pressure gauge and reinstall schrader valve cap. 28. Disconnect fuel lines from fuel manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1482 29. Remove junction block splash shield. See Figure 19. 30. Disconnect positive leads from starter relay. Refer to Figure 20. 31. Unclip two (2) mega-fuses from bracket. Refer to Figure 20. 32. Disconnect two (2) 42-pin bulkhead electrical connectors. Refer to Figure 20. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1483 33. Remove both bulkhead electrical connector halves from bracket. See Figure 20. 34. Disconnect 16-pin electrical connector. Refer to Figure 21. 35. Disconnect single-pin electrical connector. Refer to Figure 21. 36. Remove junction block bracket. See Figure 21. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1484 37. Remove heater supply hose from vehicle. Refer to Figure 22. 38. Disconnect heater return hose from heater core fitting. Then position hose away from right cam cover. Refer to Figure 22. 39. Remove ground strap to bulkhead retaining bolt, then unwrap ground strap from fuel manifold. See Figure 22. 40. Remove PCV valve and line from vehicle. 41. On 4.6L engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1485 ^ Disconnect right side coil pack electrical connector. Refer to Figure 23. ^ Disconnect right side radio interference suppressor electrical connector. Refer to Figure 23. ^ Disconnect ignition wires from right side coil pack. See Figure 23. ^ Remove right side coil pack from vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1486 ^ Unclip right side fuel charge harness from cam cover studs. Refer to Figure 24. ^ Unclip ignition wire separators from right cam cover studs. See Figure 24. ^ Disconnect ignition wires from right side spark plugs. Route ignition wires to front of engine. ^ Disconnect right side fuel injector electrical connectors. ^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. Refer to Figure 25. ^ Disconnect water temperature sender electrical connector. Refer to Figure 25. ^ Remove tie strap retaining alternator wiring harness to fuel manifold. See Figure 25. 42. On 5.4L engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1487 ^ Disconnect right side radio interference suppressor. See Figure 26. ^ Disconnect ignition coil electrical connectors from right side of engine. Refer to Figure 27. ^ Disconnect fuel injector electrical connectors from right side of engine. See Figure 27. ^ Remove right side fuel charge harness from cam cover studs, then position harness away from cam cover. ^ Remove right side ignition coils from vehicle. ^ Remove tie strap retaining alternator wiring harness to fuel manifold. 43. Disconnect upper radiator hose from thermostat housing. 44. Remove drive belt. 45. Remove alternator and mounting bracket as an assembly. The ignition wires and the alternator wiring harness will also be removed with the alternator assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1488 46. Disconnect cylinder head temperature (CHT) sensor electrical connector. Refer to Figure 28. 47. Disconnect tuning valve electrical connector. See Figure 28. 48. Remove the intake manifold retaining bolts. See Figure 29. 49. Remove intake manifold from vehicle. 50. Remove and discard intake manifold gaskets. NOTE: On 5.4L engine, cam cover bolts cannot be separated from cam cover. NOTE: Be careful not to damage cam cover gaskets, as they will be reused. Remove both camshaft covers. 51. Remove both camshaft covers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1489 52. Disconnect heater return hose from coolant tube, then remove heater hose from vehicle. Refer to Figure 30. 53. Remove retainers securing routing bracket to rear of right-hand cylinder head, then remove routing bracket and ground strap. Refer to Figure 30. 54. Remove coolant tube retainers securing coolant tube to rear of right hand cylinder head, then remove coolant tube. See Figure 30. 55. Remove jack handle from radiator air deflector. 56. Remove air deflector on top of radiator. 57. Disconnect coolant recovery hose from radiator. 58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, remove cooling fan and clutch assembly. 59. Remove cooling fan shroud. 60. On automatic transmission models, disconnect transmission lines from radiator. 61. Disconnect lower radiator hose from radiator. 62. Remove radiator support brackets, then the radiator. 63. Remove water pump pulley, then the water pump. 64. On 4.6L and 5.4L Windsor engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1490 ^ Remove two (2) upper power steering pump retaining bolts. Refer to Figure 31. ^ Raise vehicle. ^ Remove one (1) lower power steering pump retaining bolt, then position power steering pump away from front engine cover. See Figure 31. 65. On Romeo engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1491 ^ Remove two (2) upper power steering pump retaining bolts. See Figure 32. ^ Raise vehicle. NOTE: One of the following bolts cannot be completely removed from the power steering pump due to clearance with the power steering line. ^ Remove two (2) lower power steering pump retaining bolts, then position power steering pump away from front engine cover. See Figure 33. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1492 66. Remove four (4) front oil pan bolts. See Figure 34. 67. Lower vehicle. 68. Using Crankshaft Damper Remover T58P-6316-D, remove crankshaft pulley. 69. Using Front Cover Seal Remover T74P-6700-A, remove engine front cover oil seal. 70. Remove idler pulley from right side of engine front cover. This pulley blocks a front cover bolt. 71. Remove engine front cover retainers. See Figure 35. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1493 72. Remove engine front cover from engine. See Figure 36. 73. Remove crankshaft sensor ring. 74. Using Crankshaft Holding Tool T93P-6303-A, rotate crankshaft until crankshaft keyway points to the 12 o'clock position. See Figure 37. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1494 75. Install Camshaft Holding Tool T96T-6256-B, on each camshaft. See Figure 38 for holding tool placement. 76. Remove both timing chain tensioners. See Figure 39. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1495 77. Remove both timing chain tensioner guides. See Figure 40. 78. Lift right-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. Refer to Figure 41. 79. Lift left-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. See Figure 41. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1496 80. Remove both timing chain guides. See Figures 42 and 43. NOTE: Removal of this wheel opening molding screw is necessary to access all screws for the fender splash shield. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1497 81. On 4X4 models, remove one (1) screw shown in Figure 44, from both wheel opening moldings. 82. Remove both front fender splash shields. See Figure 45. 83. Raise vehicle. 84. Disconnect exhaust Y-pipe from exhaust manifolds. 85. Slightly lower vehicle. Exhaust manifold retainers will be accessed through the wheel well opening. 86. Remove left side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged. 87. Loosen engine oil indicator tube; then turn tube away from cylinder head. Removal of indicator tube is not necessary. 88. Remove right side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged. 89. Remove retainer securing transmission indicator tube to right cylinder head if equipped. NOTE: Cylinder head bolts that are under the camshaft holding tools cannot be completely removed from the head due to clearance with the holding tool. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1498 Completely loosen these bolts. 90. Remove both cylinder heads. See Figure 46. Discard all cylinder head bolts. 91. Remove and discard both cylinder head gaskets. 92. On Romeo engines, proceed as follows: ^ Remove spark plugs from right cylinder head. ^ Remove camshaft sprocket from right side camshaft. ^ Remove Camshaft Holding Tool from right side camshaft. ^ Install camshaft sprocket on new right side camshaft. Do not final tighten retaining bolt at this time. ^ Remove spark plugs from left cylinder head. ^ Remove camshaft sprocket from left side camshaft. ^ Remove Camshaft Holding Tool from left side camshaft. ^ Install camshaft sprocket on new left side camshaft. Do not final tighten retaining bolt at this time. ^ Remove power steering reservoir bracket and CHT sensor from left cylinder head. 93. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Remove Camshaft Holding Tools from both camshafts. ^ Remove power steering reservoir bracket and Cylinder Head Temperature sensor from left cylinder head. ^ Remove all eight (8) spark plugs from cylinder heads. 94. Clean the following gasket surfaces: ^ Cylinder block to cylinder head. ^ Engine front cover. ^ Water pump. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1499 ^ Intake manifold. ^ Both cam covers. Installation 1. On all cylinder heads, install one (1) pipe plug into the rear of each cylinder head in locations shown in Figure 47. 2. On 4.6L Romeo engines, install one (1) pipe plug into the front of each cylinder head in locations shown in Figure 48. 3. Install CHT sensor to left cylinder head. Tighten sensor to 24-28 Nm (17-20 lb-ft). 4. Install power steering bracket to left cylinder head. 5. Install all spark plugs (both sides). Tighten plugs to 9-20 Nm (81-178 lb-in). 6. Install right cylinder head gasket. 7. Install right cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1500 8. Tighten right cylinder head bolts in sequence shown in Figure 49 in the following three (3) stages: ^ Stage 1: 37-43 Nm (27-32 lb-ft). ^ Stage 2: Rotate 85-95 degrees. ^ Stage 3: Rotate 85-95 degrees. 9. Lubricate all camshaft journals. 10. Install left cylinder head gasket. 11. Install left cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1501 12. Tighten left cylinder head bolts in sequence shown in Figure 50 in the following three (3) stages: ^ Stage 1: 37-43 Nm (27-32 lb-ft). ^ Stage 2: Rotate 85-95 degrees. ^ Stage 3: Rotate 85-95 degrees. 13. Lubricate all camshaft journals. 14. Raise vehicle. 15. Install transmission indicator tube retainer to right cylinder head if equipped. Tighten retainer to 18-23 Nm (14-16 lb-ft). 16. Install right side exhaust manifold gasket. NOTE: Due to clearance, the exhaust system Y-pipe mounting flange cannot be positioned on the exhaust manifold outlet after the exhaust manifold is installed on the cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1502 17. Install right side exhaust manifold and gasket. Align exhaust system Y-pipe mounting flange with the studs in the exhaust manifold outlet before completely installing the exhaust manifold on the cylinder block. Tighten right side exhaust manifold retainers in sequence shown in Figure 51 to 18-22 Nm (13-16 lb-ft). 18. Position engine oil indicator tube in installed position. 19. Install left side exhaust manifold and gasket. Tighten retainers in sequence shown in Figure 52 to 18-22 Nm (13-16 lb-ft). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1503 20. Remove oil pan drain plug. Completely drain any fluid (oil, coolant) from oil pan. Reinstall drain plug, tightening to 11-16 Nm (98-143 lb-in). 21. Replace oil filter. 22. Install exhaust system Y-pipe to exhaust manifolds. Tighten retainers to 34-46 Nm (25-34 lb-ft). 23. Lower vehicle. 24. Install both fender splash shields. Tighten retainers to 10-13 Nm (89-115 lb-in). 25. On 4X4 models, install one screw removed from both wheel opening moldings. 26. On Romeo engines, proceed as follows: ^ Using socket on camshaft sprocket bolt, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53. ^ Using socket on camshaft sprocket bolt, rotate right camshaft until timing mark is in 11 o'clock position. Refer to Figure 53. 27. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Using Camshaft Positioning Tool T96T-6256-AR, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53. ^ Using Camshaft Positioning Tool T96T-6256-AR, rotate right camshaft until timing mark is in 11 o'clock position. See Figure 53. ^ Install Camshaft Holding Tool T96T-6256-B on each camshaft. 28. On Romeo engines, tighten both camshaft sprocket bolts to 110-130 Nm (81-95 lb-ft). CAUTION Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and/or valve damage can occur. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1504 29. Rotate crankshaft using Crankshaft Holding Tool T93P-6303-A. See Figure 54. Fully install holding tool. This will position crankshaft keyway to about 10:30 position. 30. Remove Crankshaft Holding Tool. 31. Compress timing chain tensioner plunger as follows: CAUTION Do not compress the ratchet assembly. This will damage the ratchet assembly. CAUTION Use protective vocers over jaws of vise to prevent damage to tensioner. ^ Compress tensioner plunger using edge of vise. See Figure 55. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1505 ^ Using small screwdriver or pick, push back and hold ratchet mechanism. See Figure 56. ^ While holding ratchet mechanism, push ratchet arm back into tensioner housing. See Figure 57. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1506 ^ Install paper clip into hole in tensioner housing. This will hold ratchet assembly and plunger in during installation. See Figure 58. ^ Remove tensioner from vise. ^ Repeat procedure for second tensioner. 32. If copper links are not visible, mark one (1) link on each end of the timing chain. One link will be an inside link. Use these marks as timing marks. See Figure 59. Repeal this step for other timing chain, if necessary. 33. Install right side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in). 34. Install left side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in). 35. Install timing chains and sprockets as follows: ^ Position left side crankshaft sprocket in left side timing chain. Make sure crankshaft sprocket hub is facing outward. Align mark on timing chain with corresponding dot on crankshaft sprocket. ^ Slide left side sprocket and chain on crankshaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1507 ^ Position left side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned. ^ Position right side crankshaft sprocket in right side timing chain. Make sure crankshaft sprocket hub is facing inward. Align mark on timing chain with corresponding dot on crankshaft sprocket. ^ Slide right side sprocket and chain on crankshaft. ^ Position right side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned. ^ Make sure marks on timing chain are lined up with corresponding dots on crankshaft and camshaft sprockets. See Figure 60. ^ Make sure right side crankshaft sprocket is in front of left side crankshaft sprocket with hubs facing each other. See Figure 61. 36. Install right and left timing chain tensioner guides. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1508 37. Install right and left timing chain tensioners. Tighten retainers to 20-30 Nm (15-20 lb-ft). 38. Remove paper clips from both timing chain tensioners. 39. Remove both camshaft holding tools. 40. Install crankshaft sensor ring. 41. Install engine front cover as follows: NOTE: The engine front cover must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, along head to block surface and oil pan to block surface. See Figure 62. ^ Using new gasket, install engine front cover. Align cover with cylinder block dowel. ^ Loosely install engine front cover bolts and stud bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1509 ^ Tighten first five (5) engine front cover bolts in sequence shown in Figure 63, to 20-30 Nm (15-22 lb-ft). ^ Tighten remaining ten (10) engine front cover bolts in sequence shown in Figure 64. On Romeo engines, tighten bolts to 20-30 Nm (15-22 lb-ft). On 4.6L and 5.4L Windsor engines, tighten bolts to 40-55 Nm (29-40 lb-ft). 42. Install right side idler pulley. Tighten retainer to 20-30 Nm (15-22 lb-ft). 43. Using clean engine oil, lubricate engine front cover oil seal inner lip. 44. Using Crankshaft Seal Replacer/Aligner T88T-6701-A, install front cover oil seal. 45. Install crankshaft pulley as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1510 NOTE: The crankshaft pulley must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to woodruff key slot on crankshaft pulley. See Figure 65. ^ Using Crankshaft Damper Replacer T74P-6316-B, install crankshaft pulley. ^ Loosely install crankshaft pulley bolt. ^ Tighten crankshaft pulley bolt to 90 Nm (66 lb-ft). ^ Loosen crankshaft pulley bolt one (1) full turn. ^ Tighten crankshaft pulley bolt to 47-53 Nm (34-39 lb-ft). ^ Tighten crankshaft pulley bolt an additional 85-90 degrees (1/4 turn). 46. On Romeo engines, proceed as follows: ^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft). ^ Raise vehicle. ^ Install two (2) power steering pump lower retaining bolts. Tighten bolt to 20-30 Nm (15-22 lb-ft). 47. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft). ^ Raise vehicle. ^ Install power steering pump lower retaining bolt. Tighten bolt to 20-30 Nm (15-22 lb-ft). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1511 48. Loosely install four (4) front oil pan bolts. Tighten bolts in sequence shown in Figure 66, in the following two (2) stages: ^ Stage 1: 20 Nm (15 lb-ft). ^ Stage 2: Rotate an additional 60 degrees. 49. Lower vehicle. 50. Using coolant, lubricate new water pump O-ring seal. Install seal on water pump. 51. Install water pump. Tighten retainers in sequence shown in Figure 67, to 20-30 Nm (15-22 lb-ft). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1512 52. Install water pump pulley. Tighten retainers in sequence shown in Figure 68, to 20-30 Nm (15-22 lb-ft). 53. Install radiator. Make sure radiator is sitting on mounting insulators. 54. Install radiator supports. Tighten retainers to 25-35 Nm (18-26 lb-ft). 55. Connect lower radiator hose to radiator. 56. On automatic transmission models, connect transmission cooler lines to radiator. Tighten lines to 16-24 Nm (12-18 lb-ft). 57. Install cooling fan shroud. Tighten retainer 108-10 Nm (71-89 lb-in). 58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, install cooling fan and clutch assembly. 59. Connect coolant recovery hose to radiator. 60. Install air deflector on top of radiator. 61. Install jack handle on radiator air deflector. 62. Using clean coolant, lubricate coolant tube O-ring seal. Install coolant tube. Tighten retainers on rear of right cylinder head to 40-55 Nm (29-40 lb-ft). NOTE: Make sure left side fuel charge harness is between routing bracket and cylinder head. 63. Install routing bracket and ground strap to rear of right cylinder head. Tighten retainers to 9-12 Nm (80-107 lb-in). 64. Install heater return hose to coolant tube. 65. Install cam cover gaskets on both cam covers. NOTE: The cam cover must be installed within four (4) minutes after applying silicone. 66. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1513 67. Install right side cam cover. Tighten retainers in sequences shown in Figures 69 and 70, to 8-12 Nm (71-107 lb-in). NOTE: The cam cover must be installed within four (4) minutes after applying silicone. 68. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1514 69. Install left side cam cover. Tighten retainers in sequences shown in Figures 71 and 72, to 8-12 Nm (71-107 lb-in). 70. Install new intake manifold gaskets. 71. Install intake manifold (including thermostat housing). Tighten bolts in sequence shown in Figure 73, in the following two (2) stages: ^ Stage 1: 2 Nm (18 lb-in). ^ Stage 2: 20-30 Nm (15-22 lb-ft). 72. Loosely position left side fuel charge harness on cam cover. 73. Connect tuning valve electrical connector. 74. Connect CHT sensor electrical connector. 75. Install alternator assembly. Tighten front alternator bolts to 21-28 Nm (15-21 lb-ft). Tighten alternator bracket bolts to 9-12 Nm (80-106 lb-in). 76. Install drive belt. 77. Using tie strap, retain alternator wiring harness to fuel manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1515 78. On 4.6L engines, proceed as follows: ^ Loosely position right side fuel charge harness on cam cover. ^ Connect water temperature sensor electrical connector. ^ Connect ECT sensor electrical connector. ^ Connect right side ignition wires to spark plugs. ^ Clip ignition wire separators to right cam cover. ^ Connect right side fuel injector electrical connectors. ^ Clip right side fuel charge harness to cam cover. ^ Install right side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft). ^ Connect ignition wires to right side coil. ^ Connect right side radio interference suppressor electrical connector. ^ Connect right side coil pack electrical connector. 79. On 5.4L engines, proceed as follows: ^ Install right side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in). ^ Position right side fuel charge harness on cam cover studs. ^ Connect right side fuel injector electrical connectors. ^ Connect right side ignition coil electrical connectors. ^ Connect right side radio interference suppressor. 80. Install PCV valve and line assembly. 81. Connect ground strap to bulkhead. 82. Connect heater return hose to heater core. 83. Install heater supply hose. 84. Install junction block bracket. Tighten retainers securely. 85. Connect single-pin electrical connector. 86. Connect 16-pin electrical connector. 87. Install both 42-pin bulkhead electrical connector halves to junction block bracket. 88. Connect both 42-pin bulkhead electrical connectors. Tighten retainers to 4-5 Nm (35-44 lb-in). 89. Clip two (2) mega-fuses to junction block bracket. 90. Connect positive leads to starter relay. 91. Install junction block bracket splash shield. 92. Connect fuel lines to fuel manifold. 93. On 4.6L engines, proceed as follows: ^ Connect left side ignition wires to spark plugs. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1516 ^ Clip ignition wire separators to left cam cover. ^ Connect left side fuel injector electrical connectors. ^ Clip left side fuel charge harness to cam cover. ^ Install left side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft). ^ Connect ignition wires to left side coil. ^ Connect left side radio interference suppressor electrical connector. ^ Connect CMP electrical connector. ^ Connect left side coil pack electrical connector. ^ Connect DPFE transducer electrical connector. ^ Connect IAC motor electrical connector. ^ Connect TP sensor electrical connector. ^ Connect EVR solenoid electrical connector. ^ Connect crankcase vent tube to left cam cover. ^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft). 94. On 5.4L engines, proceed as follows: ^ Install left side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in). ^ Connect left side fuel injector electrical connectors. ^ Connect left side ignition coil electrical connectors. ^ Connect ECT sensor electrical connector. ^ Connect TP sensor electrical connector. ^ Connect EVR solenoid electrical connector. ^ Connect DPFE transducer electrical connector. ^ Connect left side radio interference suppressor electrical connector. ^ Connect IAC motor electrical connector. ^ Connect brake booster vacuum line to throttle body adapter, then install brake booster vacuum line bracket to intake manifold. ^ Connect VMV purge line to top of throttle body adapter. ^ Position vacuum harness on top of motor. ^ Connect vacuum tap to right side of throttle body adapter. ^ Connect EVR solenoid vacuum line. ^ Connect EGR valve vacuum line. ^ Connect fuel pressure regulator vacuum line. ^ Connect vapor management valve vacuum line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1517 95. Connect EGR tube to EGR valve. Hand-tighten fitting at this time. 96. Connect DPFE transducer hoses to EGR tube. 97. On 4X4 models, connect A/C clutch electrical connector. 98. Raise vehicle. 99. Connect EGR tube to exhaust manifold. Tighten fitting to 35-45 Nm (26-33 lb-ft). 100. On 4X2 models, connect A/C clutch electrical connector. 101. Connect CKP sensor electrical connector. 102. Connect oil pressure switch electrical connector. 103. Lower vehicle. 104. Final tighten EGR tube to valve to 35-45 Nm (26-33 lb-ft). 105. On 4.6L engines, proceed as follows: ^ Loosely position vacuum harness over engine. ^ Connect EVR solenoid vacuum line. ^ Connect EGR valve vacuum line. ^ Connect fuel pressure regulator vacuum line. ^ Connect vapor management valve vacuum line. ^ Position brake booster vacuum line in installed position. Connect line to tap on throttle body adapter. Tighten line retainer at EGR valve to 8-12 Nm (71-106 lb-in). ^ Connect vacuum tap on right side of throttle body adapter. ^ Connect VMV vacuum line at rear of throttle body adapter. 106. On 5.4L engines, proceed as follows: ^ Connect crankcase vent tube to left cam cover. ^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft). 107. Position accelerator/speed control cables on top of engine. Secure cables to clip on power steering reservoir. 108. Install accelerator cable bracket to intake manifold. Tighten retainer to 6-8 Nm (53-71 lb-in). 109. Connect accelerator cable, speed control cable and return spring to throttle body. 110. Connect upper radiator hose to thermostat housing. 111. Install rear half of air cleaner. 112. Install front half of air cleaner and clean air lube. 113. Connect IAT and MAF electrical connectors. 114. Install throttle body shield. 115. Connect battery negative cable. 116. Remove memory saver. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1518 117. Fill engine with new engine oil. 118. Fill cooling system as follows: ^ Add 50/50 coolant mixture to radiator coolant recovery reservoir. ^ Install radiator cap. ^ Move temperature blend selector to full warm position. ^ Run engine until it reaches operating temperature. ^ Add 50/50 coolant mixture to radiator coolant recovery reservoir until the coolant level is between the "COOLANT FILL LEVEL" marks. ^ Turn off engine and allow cooling system to cool. ^ Repeat bulleted steps until radiator coolant recovery reservoir level remains in between fill level marks when engine is cool. 119. On air suspension equipped models, turn air suspension switch to ON position. 120. Check engine for proper operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1519 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1520 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1521 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1522 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1523 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 01-23-6 > Nov > 01 > Engine Coolant - Propylene Glycol Recommendations Coolant: All Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 01-23-6 > Nov > 01 > Engine Coolant - Propylene Glycol Recommendations > Page 1529 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement Technical Service Bulletin # 98B33 Date: 990401 Campaign - Coolant/Cylinder Head Replacement OWNER NOTIFICATION PROGRAM 98B33 Certain 1997 and 1998 Expedition, F-150 and 1998 Navigator vehicles equipped with 4.6L and 5.4L engines for inspection of coolant and, if necessary, replacement of engine cylinder heads ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Requirements ^ Attachment IIIA ^ A - Coolant Test Instructions ^ Attachment IIIB ^ B - Cylinder Head Replacement Instructions ^ Attachment IV ^ Copy of Lincoln Commitment Special Handling Procedure Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1534 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1535 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles on the enclosed list. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1536 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with this special handling procedure. CLAIMS Enter claims using DWE. See ACESII Manual. To claim for the "Lincoln Commitment Special Handling", follow the instructions on Attachment IV. OWNER REFUNDS See ACESII Manual, Section 3 for submission procedures. For owner-paid repairs of cracked cylinder heads or damage directly related to cracked cylinder heads made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from servicing dealer), enter using DWE: RENTAL CARS If cylinder head replacement is necessary, Ford will pay for a loaner or rental vehicle except for fuel and insurance which will be at the owner's expense. Do not provide a rental vehicle while cylinder heads are on order. Rentals should be provided only while the vehicle is at the dealership for cylinder head replacement. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days vehicle was used in the Miscellaneous Expense area of the recall claim. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1537 COOLANT TESTER Coolant concentrate test kits will be sent at no charge 10 dealers with affected vehicles. Additional stock of testers is limited, but testers may be ordered from the Recall Hotline 1-800-325-5621. PARTS REQUIREMENTS Parts Ordering Information Cylinder head kits can be ordered by calling the Recall Hotline at 1-800-325-5621. The kits listed contain all parts necessary for cylinder head replacement except coolant, oil and oil filter: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1538 DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 98B33 ^ Labor Operation: (see Labor Allowances) See the ACESII manual for detailed instructions. Attachment IIIA - A-Coolant Test Instructions SERVICE PROCEDURE 1. Open hood. 2. Remove coolant recovery bottle cap. 3. Run engine until normal operating temperature (thermostat open) is reached. 4. Insert supplied glycol tester (Thexton 106) into coolant recovery bottle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1539 5. Fill tester to level shown in Figure 1. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1540 ^ If five (5) or less discs float, refer to Figure 2, no service action is needed. Return vehicle to customer. ^ If all six (6) discs float, indicating "NOT SAFE" glycol condition, see Figure 2, call Recall Hotline at 1-800-325-5621 to order cylinder head kit. Perform cylinder head replacement, when kit arrives. Removal Removal 1. On air suspension equipped vehicles, turn air suspension switch, located in the RH kick panel area, to the OFF position. 2. Install memory saver, then disconnect battery negative cable. 3. Remove shield covering throttle body assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1541 4. Disconnect mass air flow (MAF) sensor electrical connector. Refer to Figure 1. 5. Disconnect intake air temperature (IAT) sensor electrical connector. Refer to Figure 1. 6. Remove air cleaner half and clean air tube as an assembly. See Figure 1. 7. Remove remaining half of air cleaner. 8. Disconnect accelerator cable, speed control cable and return spring from throttle body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1542 9. Remove accelerator cable bracket from intake manifold, then unclip cables from clip on power steering reservoir bracket. See Figure 2. Position cable assembly aside. 10. On 4.6L engines, proceed as follows: ^ Disconnect vapor management valve (VMV) vacuum line at rear of throttle body adapter. Refer to Figure 3. ^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 3. ^ Disconnect PCV hose at rear of throttle body adapter. Refer to Figure 3. ^ Remove brake booster vacuum line retainer at EGR valve. Disconnect vacuum line at throttle body adapter. See Figure 3. Position line aside. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1543 ^ Disconnect vapor management valve (VMV) vacuum line. Refer to Figure 4. ^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 4. ^ Disconnect EGR valve vacuum line. Refer to Figure 4. ^ Disconnect EVR solenoid vacuum line. See Figure 4. ^ Position vacuum harness away from engine. 11. On 5.4L engines, proceed as follows: ^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 5. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1544 ^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle. 12. Raise vehicle. 13. Disconnect EGR tube from exhaust manifold. 14. Disconnect oil pressure switch electrical connector. See Figure 6. 15. Disconnect crankshaft position (CKP) sensor electrical connector. See Figure 7. 16. On 4X2 models, disconnect A/C clutch electrical connector. 17. Drain coolant from radiator. NOTE: Do not remove right side cylinder block coolant drain plug. 18. Remove left side cylinder block coolant drain plug. Allow coolant to completely drain. 19. Install cylinder block coolant drain plug. Tighten plug to 16-24 Nm (12-17 lb-ft). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1545 20. Drain engine oil. Do not final tighten drain plug at this time, as it will be removed again. 21. Lower vehicle. NOTE: The best access to the A/C electrical connector is through the wheel well. 22. On 4X4 models, disconnect A/C clutch electrical connector. 23. Mark and disconnect DPFE transducer hoses from EGR tube. 24. Disconnect EGR tube from EGR valve, then remove EGR tube from vehicle. 25. On 4.6L engines, proceed as follows: ^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 8. ^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1546 ^ Disconnect EVR solenoid electrical connector. Refer to Figure 9. ^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 9. ^ Disconnect Idle Air Control (IAC) motor electrical connector. Refer to Figure 9. ^ Disconnect DPFE transducer electrical connector. See Figure 9. ^ Disconnect left side coil pack electrical connector. Refer to Figure 10. ^ Disconnect camshaft position (CMP) sensor electrical connector. Refer to Figure 10. ^ Disconnect left side radio interference suppressor electrical connector. See Figure 10. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1547 ^ Disconnect ignition wires from left side coil pack. ^ Remove left side coil pack from vehicle. ^ Unclip left side fuel charge harness from cam cover studs. Refer to Figure 11. ^ Unclip ignition wire separators from left cam cover studs. See Figure 11. ^ Disconnect ignition wires from left side spark plugs. Route ignition wires to front of engine. ^ Disconnect left side fuel injector electrical connectors. 26. On 5.4L engines, proceed as follows: ^ Disconnect Vapor Management Valve (VMV) vacuum line. Refer to Figure 12. ^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 12. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1548 ^ Disconnect EGR valve vacuum line. Refer to Figure 12. ^ Disconnect EVR solenoid vacuum line. See Figure 12 ^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 13. ^ Position vacuum harness away from engine. ^ Disconnect VMV purge line at top of throttle body adapter. See Figure 13. ^ Disconnect brake booster vacuum line from throttle body adapter. ^ Remove brake booster vacuum line bracket from intake manifold. Position vacuum line assembly away from intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1549 ^ Disconnect Idle Air Control (IAC) motor electrical connector. See Figure 14. ^ Disconnect left side radio interference suppressor electrical connector. Refer to Figure 15. ^ Disconnect DPFE transducer electrical connector. Refer to Figure 15. ^ Disconnect EVR solenoid electrical connector. Refer to Figure 15. ^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 15. ^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1550 ^ Disconnect camshaft position (CMP) sensor electrical connector. See Figure 16. ^ Disconnect ignition coil electrical connectors from left side of engine. Refer to Figure 17. ^ Disconnect fuel injector electrical connectors from left side of engine. See Figure 17. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1551 ^ Remove left side fuel charge harness from cam cover studs, then position harness away from cam cover. See Figure 18. ^ Remove left side ignition coils from vehicle. WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 27. Relieve fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on EFI/CFI fuel pressure gauge. ^ Remove fuel pressure gauge and reinstall schrader valve cap. 28. Disconnect fuel lines from fuel manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1552 29. Remove junction block splash shield. See Figure 19. 30. Disconnect positive leads from starter relay. Refer to Figure 20. 31. Unclip two (2) mega-fuses from bracket. Refer to Figure 20. 32. Disconnect two (2) 42-pin bulkhead electrical connectors. Refer to Figure 20. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1553 33. Remove both bulkhead electrical connector halves from bracket. See Figure 20. 34. Disconnect 16-pin electrical connector. Refer to Figure 21. 35. Disconnect single-pin electrical connector. Refer to Figure 21. 36. Remove junction block bracket. See Figure 21. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1554 37. Remove heater supply hose from vehicle. Refer to Figure 22. 38. Disconnect heater return hose from heater core fitting. Then position hose away from right cam cover. Refer to Figure 22. 39. Remove ground strap to bulkhead retaining bolt, then unwrap ground strap from fuel manifold. See Figure 22. 40. Remove PCV valve and line from vehicle. 41. On 4.6L engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1555 ^ Disconnect right side coil pack electrical connector. Refer to Figure 23. ^ Disconnect right side radio interference suppressor electrical connector. Refer to Figure 23. ^ Disconnect ignition wires from right side coil pack. See Figure 23. ^ Remove right side coil pack from vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1556 ^ Unclip right side fuel charge harness from cam cover studs. Refer to Figure 24. ^ Unclip ignition wire separators from right cam cover studs. See Figure 24. ^ Disconnect ignition wires from right side spark plugs. Route ignition wires to front of engine. ^ Disconnect right side fuel injector electrical connectors. ^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. Refer to Figure 25. ^ Disconnect water temperature sender electrical connector. Refer to Figure 25. ^ Remove tie strap retaining alternator wiring harness to fuel manifold. See Figure 25. 42. On 5.4L engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1557 ^ Disconnect right side radio interference suppressor. See Figure 26. ^ Disconnect ignition coil electrical connectors from right side of engine. Refer to Figure 27. ^ Disconnect fuel injector electrical connectors from right side of engine. See Figure 27. ^ Remove right side fuel charge harness from cam cover studs, then position harness away from cam cover. ^ Remove right side ignition coils from vehicle. ^ Remove tie strap retaining alternator wiring harness to fuel manifold. 43. Disconnect upper radiator hose from thermostat housing. 44. Remove drive belt. 45. Remove alternator and mounting bracket as an assembly. The ignition wires and the alternator wiring harness will also be removed with the alternator assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1558 46. Disconnect cylinder head temperature (CHT) sensor electrical connector. Refer to Figure 28. 47. Disconnect tuning valve electrical connector. See Figure 28. 48. Remove the intake manifold retaining bolts. See Figure 29. 49. Remove intake manifold from vehicle. 50. Remove and discard intake manifold gaskets. NOTE: On 5.4L engine, cam cover bolts cannot be separated from cam cover. NOTE: Be careful not to damage cam cover gaskets, as they will be reused. Remove both camshaft covers. 51. Remove both camshaft covers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1559 52. Disconnect heater return hose from coolant tube, then remove heater hose from vehicle. Refer to Figure 30. 53. Remove retainers securing routing bracket to rear of right-hand cylinder head, then remove routing bracket and ground strap. Refer to Figure 30. 54. Remove coolant tube retainers securing coolant tube to rear of right hand cylinder head, then remove coolant tube. See Figure 30. 55. Remove jack handle from radiator air deflector. 56. Remove air deflector on top of radiator. 57. Disconnect coolant recovery hose from radiator. 58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, remove cooling fan and clutch assembly. 59. Remove cooling fan shroud. 60. On automatic transmission models, disconnect transmission lines from radiator. 61. Disconnect lower radiator hose from radiator. 62. Remove radiator support brackets, then the radiator. 63. Remove water pump pulley, then the water pump. 64. On 4.6L and 5.4L Windsor engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1560 ^ Remove two (2) upper power steering pump retaining bolts. Refer to Figure 31. ^ Raise vehicle. ^ Remove one (1) lower power steering pump retaining bolt, then position power steering pump away from front engine cover. See Figure 31. 65. On Romeo engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1561 ^ Remove two (2) upper power steering pump retaining bolts. See Figure 32. ^ Raise vehicle. NOTE: One of the following bolts cannot be completely removed from the power steering pump due to clearance with the power steering line. ^ Remove two (2) lower power steering pump retaining bolts, then position power steering pump away from front engine cover. See Figure 33. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1562 66. Remove four (4) front oil pan bolts. See Figure 34. 67. Lower vehicle. 68. Using Crankshaft Damper Remover T58P-6316-D, remove crankshaft pulley. 69. Using Front Cover Seal Remover T74P-6700-A, remove engine front cover oil seal. 70. Remove idler pulley from right side of engine front cover. This pulley blocks a front cover bolt. 71. Remove engine front cover retainers. See Figure 35. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1563 72. Remove engine front cover from engine. See Figure 36. 73. Remove crankshaft sensor ring. 74. Using Crankshaft Holding Tool T93P-6303-A, rotate crankshaft until crankshaft keyway points to the 12 o'clock position. See Figure 37. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1564 75. Install Camshaft Holding Tool T96T-6256-B, on each camshaft. See Figure 38 for holding tool placement. 76. Remove both timing chain tensioners. See Figure 39. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1565 77. Remove both timing chain tensioner guides. See Figure 40. 78. Lift right-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. Refer to Figure 41. 79. Lift left-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. See Figure 41. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1566 80. Remove both timing chain guides. See Figures 42 and 43. NOTE: Removal of this wheel opening molding screw is necessary to access all screws for the fender splash shield. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1567 81. On 4X4 models, remove one (1) screw shown in Figure 44, from both wheel opening moldings. 82. Remove both front fender splash shields. See Figure 45. 83. Raise vehicle. 84. Disconnect exhaust Y-pipe from exhaust manifolds. 85. Slightly lower vehicle. Exhaust manifold retainers will be accessed through the wheel well opening. 86. Remove left side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged. 87. Loosen engine oil indicator tube; then turn tube away from cylinder head. Removal of indicator tube is not necessary. 88. Remove right side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged. 89. Remove retainer securing transmission indicator tube to right cylinder head if equipped. NOTE: Cylinder head bolts that are under the camshaft holding tools cannot be completely removed from the head due to clearance with the holding tool. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1568 Completely loosen these bolts. 90. Remove both cylinder heads. See Figure 46. Discard all cylinder head bolts. 91. Remove and discard both cylinder head gaskets. 92. On Romeo engines, proceed as follows: ^ Remove spark plugs from right cylinder head. ^ Remove camshaft sprocket from right side camshaft. ^ Remove Camshaft Holding Tool from right side camshaft. ^ Install camshaft sprocket on new right side camshaft. Do not final tighten retaining bolt at this time. ^ Remove spark plugs from left cylinder head. ^ Remove camshaft sprocket from left side camshaft. ^ Remove Camshaft Holding Tool from left side camshaft. ^ Install camshaft sprocket on new left side camshaft. Do not final tighten retaining bolt at this time. ^ Remove power steering reservoir bracket and CHT sensor from left cylinder head. 93. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Remove Camshaft Holding Tools from both camshafts. ^ Remove power steering reservoir bracket and Cylinder Head Temperature sensor from left cylinder head. ^ Remove all eight (8) spark plugs from cylinder heads. 94. Clean the following gasket surfaces: ^ Cylinder block to cylinder head. ^ Engine front cover. ^ Water pump. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1569 ^ Intake manifold. ^ Both cam covers. Installation 1. On all cylinder heads, install one (1) pipe plug into the rear of each cylinder head in locations shown in Figure 47. 2. On 4.6L Romeo engines, install one (1) pipe plug into the front of each cylinder head in locations shown in Figure 48. 3. Install CHT sensor to left cylinder head. Tighten sensor to 24-28 Nm (17-20 lb-ft). 4. Install power steering bracket to left cylinder head. 5. Install all spark plugs (both sides). Tighten plugs to 9-20 Nm (81-178 lb-in). 6. Install right cylinder head gasket. 7. Install right cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1570 8. Tighten right cylinder head bolts in sequence shown in Figure 49 in the following three (3) stages: ^ Stage 1: 37-43 Nm (27-32 lb-ft). ^ Stage 2: Rotate 85-95 degrees. ^ Stage 3: Rotate 85-95 degrees. 9. Lubricate all camshaft journals. 10. Install left cylinder head gasket. 11. Install left cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1571 12. Tighten left cylinder head bolts in sequence shown in Figure 50 in the following three (3) stages: ^ Stage 1: 37-43 Nm (27-32 lb-ft). ^ Stage 2: Rotate 85-95 degrees. ^ Stage 3: Rotate 85-95 degrees. 13. Lubricate all camshaft journals. 14. Raise vehicle. 15. Install transmission indicator tube retainer to right cylinder head if equipped. Tighten retainer to 18-23 Nm (14-16 lb-ft). 16. Install right side exhaust manifold gasket. NOTE: Due to clearance, the exhaust system Y-pipe mounting flange cannot be positioned on the exhaust manifold outlet after the exhaust manifold is installed on the cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1572 17. Install right side exhaust manifold and gasket. Align exhaust system Y-pipe mounting flange with the studs in the exhaust manifold outlet before completely installing the exhaust manifold on the cylinder block. Tighten right side exhaust manifold retainers in sequence shown in Figure 51 to 18-22 Nm (13-16 lb-ft). 18. Position engine oil indicator tube in installed position. 19. Install left side exhaust manifold and gasket. Tighten retainers in sequence shown in Figure 52 to 18-22 Nm (13-16 lb-ft). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1573 20. Remove oil pan drain plug. Completely drain any fluid (oil, coolant) from oil pan. Reinstall drain plug, tightening to 11-16 Nm (98-143 lb-in). 21. Replace oil filter. 22. Install exhaust system Y-pipe to exhaust manifolds. Tighten retainers to 34-46 Nm (25-34 lb-ft). 23. Lower vehicle. 24. Install both fender splash shields. Tighten retainers to 10-13 Nm (89-115 lb-in). 25. On 4X4 models, install one screw removed from both wheel opening moldings. 26. On Romeo engines, proceed as follows: ^ Using socket on camshaft sprocket bolt, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53. ^ Using socket on camshaft sprocket bolt, rotate right camshaft until timing mark is in 11 o'clock position. Refer to Figure 53. 27. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Using Camshaft Positioning Tool T96T-6256-AR, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53. ^ Using Camshaft Positioning Tool T96T-6256-AR, rotate right camshaft until timing mark is in 11 o'clock position. See Figure 53. ^ Install Camshaft Holding Tool T96T-6256-B on each camshaft. 28. On Romeo engines, tighten both camshaft sprocket bolts to 110-130 Nm (81-95 lb-ft). CAUTION Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and/or valve damage can occur. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1574 29. Rotate crankshaft using Crankshaft Holding Tool T93P-6303-A. See Figure 54. Fully install holding tool. This will position crankshaft keyway to about 10:30 position. 30. Remove Crankshaft Holding Tool. 31. Compress timing chain tensioner plunger as follows: CAUTION Do not compress the ratchet assembly. This will damage the ratchet assembly. CAUTION Use protective vocers over jaws of vise to prevent damage to tensioner. ^ Compress tensioner plunger using edge of vise. See Figure 55. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1575 ^ Using small screwdriver or pick, push back and hold ratchet mechanism. See Figure 56. ^ While holding ratchet mechanism, push ratchet arm back into tensioner housing. See Figure 57. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1576 ^ Install paper clip into hole in tensioner housing. This will hold ratchet assembly and plunger in during installation. See Figure 58. ^ Remove tensioner from vise. ^ Repeat procedure for second tensioner. 32. If copper links are not visible, mark one (1) link on each end of the timing chain. One link will be an inside link. Use these marks as timing marks. See Figure 59. Repeal this step for other timing chain, if necessary. 33. Install right side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in). 34. Install left side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in). 35. Install timing chains and sprockets as follows: ^ Position left side crankshaft sprocket in left side timing chain. Make sure crankshaft sprocket hub is facing outward. Align mark on timing chain with corresponding dot on crankshaft sprocket. ^ Slide left side sprocket and chain on crankshaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1577 ^ Position left side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned. ^ Position right side crankshaft sprocket in right side timing chain. Make sure crankshaft sprocket hub is facing inward. Align mark on timing chain with corresponding dot on crankshaft sprocket. ^ Slide right side sprocket and chain on crankshaft. ^ Position right side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned. ^ Make sure marks on timing chain are lined up with corresponding dots on crankshaft and camshaft sprockets. See Figure 60. ^ Make sure right side crankshaft sprocket is in front of left side crankshaft sprocket with hubs facing each other. See Figure 61. 36. Install right and left timing chain tensioner guides. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1578 37. Install right and left timing chain tensioners. Tighten retainers to 20-30 Nm (15-20 lb-ft). 38. Remove paper clips from both timing chain tensioners. 39. Remove both camshaft holding tools. 40. Install crankshaft sensor ring. 41. Install engine front cover as follows: NOTE: The engine front cover must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, along head to block surface and oil pan to block surface. See Figure 62. ^ Using new gasket, install engine front cover. Align cover with cylinder block dowel. ^ Loosely install engine front cover bolts and stud bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1579 ^ Tighten first five (5) engine front cover bolts in sequence shown in Figure 63, to 20-30 Nm (15-22 lb-ft). ^ Tighten remaining ten (10) engine front cover bolts in sequence shown in Figure 64. On Romeo engines, tighten bolts to 20-30 Nm (15-22 lb-ft). On 4.6L and 5.4L Windsor engines, tighten bolts to 40-55 Nm (29-40 lb-ft). 42. Install right side idler pulley. Tighten retainer to 20-30 Nm (15-22 lb-ft). 43. Using clean engine oil, lubricate engine front cover oil seal inner lip. 44. Using Crankshaft Seal Replacer/Aligner T88T-6701-A, install front cover oil seal. 45. Install crankshaft pulley as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1580 NOTE: The crankshaft pulley must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to woodruff key slot on crankshaft pulley. See Figure 65. ^ Using Crankshaft Damper Replacer T74P-6316-B, install crankshaft pulley. ^ Loosely install crankshaft pulley bolt. ^ Tighten crankshaft pulley bolt to 90 Nm (66 lb-ft). ^ Loosen crankshaft pulley bolt one (1) full turn. ^ Tighten crankshaft pulley bolt to 47-53 Nm (34-39 lb-ft). ^ Tighten crankshaft pulley bolt an additional 85-90 degrees (1/4 turn). 46. On Romeo engines, proceed as follows: ^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft). ^ Raise vehicle. ^ Install two (2) power steering pump lower retaining bolts. Tighten bolt to 20-30 Nm (15-22 lb-ft). 47. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft). ^ Raise vehicle. ^ Install power steering pump lower retaining bolt. Tighten bolt to 20-30 Nm (15-22 lb-ft). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1581 48. Loosely install four (4) front oil pan bolts. Tighten bolts in sequence shown in Figure 66, in the following two (2) stages: ^ Stage 1: 20 Nm (15 lb-ft). ^ Stage 2: Rotate an additional 60 degrees. 49. Lower vehicle. 50. Using coolant, lubricate new water pump O-ring seal. Install seal on water pump. 51. Install water pump. Tighten retainers in sequence shown in Figure 67, to 20-30 Nm (15-22 lb-ft). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1582 52. Install water pump pulley. Tighten retainers in sequence shown in Figure 68, to 20-30 Nm (15-22 lb-ft). 53. Install radiator. Make sure radiator is sitting on mounting insulators. 54. Install radiator supports. Tighten retainers to 25-35 Nm (18-26 lb-ft). 55. Connect lower radiator hose to radiator. 56. On automatic transmission models, connect transmission cooler lines to radiator. Tighten lines to 16-24 Nm (12-18 lb-ft). 57. Install cooling fan shroud. Tighten retainer 108-10 Nm (71-89 lb-in). 58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, install cooling fan and clutch assembly. 59. Connect coolant recovery hose to radiator. 60. Install air deflector on top of radiator. 61. Install jack handle on radiator air deflector. 62. Using clean coolant, lubricate coolant tube O-ring seal. Install coolant tube. Tighten retainers on rear of right cylinder head to 40-55 Nm (29-40 lb-ft). NOTE: Make sure left side fuel charge harness is between routing bracket and cylinder head. 63. Install routing bracket and ground strap to rear of right cylinder head. Tighten retainers to 9-12 Nm (80-107 lb-in). 64. Install heater return hose to coolant tube. 65. Install cam cover gaskets on both cam covers. NOTE: The cam cover must be installed within four (4) minutes after applying silicone. 66. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1583 67. Install right side cam cover. Tighten retainers in sequences shown in Figures 69 and 70, to 8-12 Nm (71-107 lb-in). NOTE: The cam cover must be installed within four (4) minutes after applying silicone. 68. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1584 69. Install left side cam cover. Tighten retainers in sequences shown in Figures 71 and 72, to 8-12 Nm (71-107 lb-in). 70. Install new intake manifold gaskets. 71. Install intake manifold (including thermostat housing). Tighten bolts in sequence shown in Figure 73, in the following two (2) stages: ^ Stage 1: 2 Nm (18 lb-in). ^ Stage 2: 20-30 Nm (15-22 lb-ft). 72. Loosely position left side fuel charge harness on cam cover. 73. Connect tuning valve electrical connector. 74. Connect CHT sensor electrical connector. 75. Install alternator assembly. Tighten front alternator bolts to 21-28 Nm (15-21 lb-ft). Tighten alternator bracket bolts to 9-12 Nm (80-106 lb-in). 76. Install drive belt. 77. Using tie strap, retain alternator wiring harness to fuel manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1585 78. On 4.6L engines, proceed as follows: ^ Loosely position right side fuel charge harness on cam cover. ^ Connect water temperature sensor electrical connector. ^ Connect ECT sensor electrical connector. ^ Connect right side ignition wires to spark plugs. ^ Clip ignition wire separators to right cam cover. ^ Connect right side fuel injector electrical connectors. ^ Clip right side fuel charge harness to cam cover. ^ Install right side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft). ^ Connect ignition wires to right side coil. ^ Connect right side radio interference suppressor electrical connector. ^ Connect right side coil pack electrical connector. 79. On 5.4L engines, proceed as follows: ^ Install right side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in). ^ Position right side fuel charge harness on cam cover studs. ^ Connect right side fuel injector electrical connectors. ^ Connect right side ignition coil electrical connectors. ^ Connect right side radio interference suppressor. 80. Install PCV valve and line assembly. 81. Connect ground strap to bulkhead. 82. Connect heater return hose to heater core. 83. Install heater supply hose. 84. Install junction block bracket. Tighten retainers securely. 85. Connect single-pin electrical connector. 86. Connect 16-pin electrical connector. 87. Install both 42-pin bulkhead electrical connector halves to junction block bracket. 88. Connect both 42-pin bulkhead electrical connectors. Tighten retainers to 4-5 Nm (35-44 lb-in). 89. Clip two (2) mega-fuses to junction block bracket. 90. Connect positive leads to starter relay. 91. Install junction block bracket splash shield. 92. Connect fuel lines to fuel manifold. 93. On 4.6L engines, proceed as follows: ^ Connect left side ignition wires to spark plugs. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1586 ^ Clip ignition wire separators to left cam cover. ^ Connect left side fuel injector electrical connectors. ^ Clip left side fuel charge harness to cam cover. ^ Install left side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft). ^ Connect ignition wires to left side coil. ^ Connect left side radio interference suppressor electrical connector. ^ Connect CMP electrical connector. ^ Connect left side coil pack electrical connector. ^ Connect DPFE transducer electrical connector. ^ Connect IAC motor electrical connector. ^ Connect TP sensor electrical connector. ^ Connect EVR solenoid electrical connector. ^ Connect crankcase vent tube to left cam cover. ^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft). 94. On 5.4L engines, proceed as follows: ^ Install left side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in). ^ Connect left side fuel injector electrical connectors. ^ Connect left side ignition coil electrical connectors. ^ Connect ECT sensor electrical connector. ^ Connect TP sensor electrical connector. ^ Connect EVR solenoid electrical connector. ^ Connect DPFE transducer electrical connector. ^ Connect left side radio interference suppressor electrical connector. ^ Connect IAC motor electrical connector. ^ Connect brake booster vacuum line to throttle body adapter, then install brake booster vacuum line bracket to intake manifold. ^ Connect VMV purge line to top of throttle body adapter. ^ Position vacuum harness on top of motor. ^ Connect vacuum tap to right side of throttle body adapter. ^ Connect EVR solenoid vacuum line. ^ Connect EGR valve vacuum line. ^ Connect fuel pressure regulator vacuum line. ^ Connect vapor management valve vacuum line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1587 95. Connect EGR tube to EGR valve. Hand-tighten fitting at this time. 96. Connect DPFE transducer hoses to EGR tube. 97. On 4X4 models, connect A/C clutch electrical connector. 98. Raise vehicle. 99. Connect EGR tube to exhaust manifold. Tighten fitting to 35-45 Nm (26-33 lb-ft). 100. On 4X2 models, connect A/C clutch electrical connector. 101. Connect CKP sensor electrical connector. 102. Connect oil pressure switch electrical connector. 103. Lower vehicle. 104. Final tighten EGR tube to valve to 35-45 Nm (26-33 lb-ft). 105. On 4.6L engines, proceed as follows: ^ Loosely position vacuum harness over engine. ^ Connect EVR solenoid vacuum line. ^ Connect EGR valve vacuum line. ^ Connect fuel pressure regulator vacuum line. ^ Connect vapor management valve vacuum line. ^ Position brake booster vacuum line in installed position. Connect line to tap on throttle body adapter. Tighten line retainer at EGR valve to 8-12 Nm (71-106 lb-in). ^ Connect vacuum tap on right side of throttle body adapter. ^ Connect VMV vacuum line at rear of throttle body adapter. 106. On 5.4L engines, proceed as follows: ^ Connect crankcase vent tube to left cam cover. ^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft). 107. Position accelerator/speed control cables on top of engine. Secure cables to clip on power steering reservoir. 108. Install accelerator cable bracket to intake manifold. Tighten retainer to 6-8 Nm (53-71 lb-in). 109. Connect accelerator cable, speed control cable and return spring to throttle body. 110. Connect upper radiator hose to thermostat housing. 111. Install rear half of air cleaner. 112. Install front half of air cleaner and clean air lube. 113. Connect IAT and MAF electrical connectors. 114. Install throttle body shield. 115. Connect battery negative cable. 116. Remove memory saver. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1588 117. Fill engine with new engine oil. 118. Fill cooling system as follows: ^ Add 50/50 coolant mixture to radiator coolant recovery reservoir. ^ Install radiator cap. ^ Move temperature blend selector to full warm position. ^ Run engine until it reaches operating temperature. ^ Add 50/50 coolant mixture to radiator coolant recovery reservoir until the coolant level is between the "COOLANT FILL LEVEL" marks. ^ Turn off engine and allow cooling system to cool. ^ Repeat bulleted steps until radiator coolant recovery reservoir level remains in between fill level marks when engine is cool. 119. On air suspension equipped models, turn air suspension switch to ON position. 120. Check engine for proper operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1589 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1590 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1591 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1592 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1593 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 01-23-6 > Nov > 01 > Engine Coolant - Propylene Glycol Recommendations Coolant: All Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 01-23-6 > Nov > 01 > Engine Coolant - Propylene Glycol Recommendations > Page 1599 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity With 1-row radiator 18 qts .............................................................................................................................................................. ................................. With 2-row radiator 19.9 qts .............................................................................................................................................................. ................................. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1602 Coolant: Fluid Type Specifications COOLANT TYPE Ethylene Glycol (EC) .............................................................................................................................................................. ........... Coolant Mixture with Water 50% .............................................................................................................................................................. ........................ Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the correct coolant type. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 1607 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 1608 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications With E4OD Transmission A/T Fluid 4x2 ....................................................................................................................................... ........................................................... 15L (15.9 Qt) A/T Fluid 4x4 ....................................................................................................................................... ........................................................ 15.5L (16.4 Qt) NOTE: With engine at operating temperature, shift through all gears. Check fluid in PARK add fluid as needed. With 4R70W Transmission A/T Fluid .............................................................................................................................................. ......................................................... 13.1L (13.9 Qt) NOTE: With engine at operating temperature, shift through all gears. Check fluid in PARK add fluid as needed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1611 Fluid - A/T: Fluid Type Specifications NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. Automatic (4R70W) ............................................................................................................................. ..................................................... MERCON V ATF Automatic (4R100) ............................................................................................................................................................. MERCON or MERCON V ATF Automatic (E40D) ............................................................................................................................................................. MERCON or MERCON V ATF NOTE: Automatic transmissions requiring MERCON V should only be serviced with MERCON V, or fluid from a container that is specified as a dual usage fluid: MERCON/MERCON V. NOTE: Automatic transmissions requiring MERCON can not be serviced with MERCON, MERCON V, or dual usage fluids labeled MERCON/MERCON V. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1612 Fluid - A/T: Diagrams PARK Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1613 PARK Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1614 PARK Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1615 PARK Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1616 2 ND GEAR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1617 2 ND GEAR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1618 TCC RELEASE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1619 TCC RELEASE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1620 LINE/SRV PRESSURE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1621 PARK NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1622 PARK NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1623 1ST GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1624 2ND GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1625 3RD GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1626 4TH GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1627 MANUAL 3RD GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1628 MANUAL 2ND GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1629 MANUAL 1ST GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Fluid Condition Check Fluid - A/T: Testing and Inspection 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. Perform diagnostic checks and adjustments; refer to the Diagnosis by Symptom Index. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Fluid Condition Check > Page 1632 Fluid - A/T: Testing and Inspection 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, city traffic, hot weather, or 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, shift slowly, or has signs of fluid leaking, the fluid level should be checked. 1. With the transmission in (P) Park, the engine at idle, foot pressed on the brake, move the range selector lever through each gear and allow engagement of each gear. Place the range selector lever in the Park position. 2. Wipe the fluid level indicator cap and remove the indicator. 3. Wipe the indicator with a clean cloth. 4. Install the indicator back in the filler tube until it is fully seated, then remove the indicator. The fluid level should be within the normal operating temperature range. HIGH FLUID LEVEL A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid from the vent tube and possible transmission malfunction and/or damage. If an overfill reading is indicated, refer to Transmission Fluid Drain and Refill. 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 other type of transmission fluid 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 Specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Page 1633 Fluid - A/T: Service and Repair 1. Normal maintenance requires periodic automatic transmission fluid changes. If a major service, such as a clutch, band, bearing, etc., is required, the automatic transmission fluid will also have to be removed for service. At this time, the torque converter, transmission cooler, cooler inlet tube and cooler tube must be thoroughly flushed to remove any dirt. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid as specified. - Normal Maintenance Change fluid at 48,279 km (30,000 miles). - Severe Duty/Major Overhaul Change fluid at 33,795 km (21,000 miles). 2. CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or failure. Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for the transmission code. 3. When filling a dry transmission and torque converter, refer to Specification chart for capacity. Check the fluid level. REMOVAL 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise and support vehicle on hoist. 4. Place a drain pan under the transmission fluid pan. 5. Drain transmission fluid. - Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 6. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. - Replace transmission fluid pan gasket as necessary. 7. Remove torque converter housing plug. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Page 1634 8. Remove the torque converter drain plug and drain the torque converter. - Rotate the crankshaft to access the drain plug. 9. Clean and inspect the (A) transmission fluid pan, (B) transmission fluid pan gasket and (C) magnet. 10. Flush the fluid cooler and fluid cooler lines. 11. Flush the torque converter. INSTALLATION 1. NOTE: A new torque converter drain plug must be used. Install the torque converter drain plug. 2. Install torque converter housing plug. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Page 1635 3. 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. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. 5. 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 transmission fluid pan gasket. 2 Position the transmission fluid pan. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Page 1636 6. Install bolts. 7. Lower the vehicle. 8. Connect the battery ground cable. 9. If equipped with air suspension, reactivate the system by turning on the air suspension switch. 10. NOTE: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). Fill transmission to proper fluid level. Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent fluid meeting MERCON V(R) specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Differential Fluid Capacity Capacity (Refill) ................................................................................................................................... .................................................................... 3.7 Pints Rear Differential Fluid Capacity Capacity (Refill) ................................................................................................................................... .................................................................... 5.8 Pints Fill no higher than 1/4 to 9/16 inch below fill plug. Add 4 oz. of friction modifier C8AZ-19B956-A for Traction-Lok differentials or equivalent meeting Ford specification EST-M2C118-A for Traction-Lok Axles. To determine standard or limited slip type, check axle code on label on door lock pillar. Standard axles consist of two numbers. Limited slip codes consist of one letter and one number. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1641 Fluid - Differential: Fluid Type Specifications Front Front Axle Fluid Ford Part Number ................................................................................................................................................. Motorcraft SAE 75W90 Axle Lubricant Rear Rear Axle Fluid Ford Part Number ....................................................................................................................... Motorcraft SAE 75W140 Synthetic Rear Axle Lubricant Note: Your vehicles rear axle is equipped with synthetic rear axle lubricant. Rear axles containing synthetic lubricant are lubricated for life. These lubricants are not to be checked or changed unless a leak is suspected, service required or the axle has been submerged in water. The axle lubricant should be changed any time the axle has been submerged in water. Add 118 ml (4 oz.) of additive friction modifier C8AZ-19B546-A, Ford specification EST-M2C118-A whenever the fluid is changed. Service refill capacities are determined by filling the rear axle 6 mm to 14 mm (1/4 inch to 9/16 inch) below the bottom of the filler hole. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Capacity Transfer Case Fluid ............................................................................................................................. ...................................................................... 2.0 Qts Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1646 Fluid - Transfer Case: Fluid Type Specifications TYPE .............................................................................................................................................................. MERCON(R) Automatic Transmission Fluid Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page 1647 Fluid - Transfer Case: Service and Repair 1. CAUTION: If the proper fill procedures are not followed, transfer case failure can result. NOTE: Fluid level must be just below the fill plug. Remove the fill plug from the rear of the transfer case, and check fluid level. If the fluid is below the level, fill with Motorcraft MERCON(R) Automatic Transmission Fluid XT-2-QDX or -DDX or MERCON(R) equivalent. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1652 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1653 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1654 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1655 Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity ............................................................................................................................................... ............................................................. 6.5L (6.9 Qt) NOTE: Listed capacities are approximate. Check fluid level after filling. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1658 Engine Oil: Fluid Type Specifications Engine Oil Type Type ..................................................................................................................................................... .......................................................................... GF-1 Viscosity .............................................................................................................................................. ...................................................................... 5W-30 NOTE: Must meet Ford Specification M2C-153-F Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 1663 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Fill to line in power steering fluid reservoir. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 1666 Power Steering Fluid: Fluid Type Specifications FLUID TYPE ........................................................................................................................................................... Ford E6AZ-19582-AA or equivalent Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1671 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1672 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1673 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1674 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1675 Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1676 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1677 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1678 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity With Aux Air ......................................................................................................................................... .................................................................... 62.0 oz. With our Aux Air ................................................ ...................................................................................................................................................... 37.0 oz. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1681 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ..................................................................... R-134a* *Meeting Ford Specification WSH-M17B19-A Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Capacity Without Auxiliary .................................................................................................................................. ...................................................... 266 ml (9 oz) With Auxiliary .......................................................... ................................................................................................................................. 414 ml (14 oz) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1686 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type ....................................................................................................................................................... Motorcraft YN-12b or Equivalent* *In Canada, CYN-12b. Oil must meet Ford Specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Compressor Oil Refrigerant Oil: Service and Repair Compressor Oil Adding Refrigerant Oil 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 for replacement, 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 replacement part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. 1 Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Compressor Oil > Page 1689 4. For the A/C condenser core, add 30 ml (1 ounce) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when performing each of the following repairs: replacement of the A/C evaporator core orifice - replacement of the A/C compressor pressure relief valve - replacement of a refrigerant line - repair of an O-ring leak - repair of a charge port leak 6. Replacement of components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Refrigerant Oil Addition 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 for replacement, 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 replacement part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor NOTE: Service A/C compressors are shipped without compressor oil. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Compressor Oil > Page 1690 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. 1 Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. 4. For the A/C condenser core, add 30 ml (1 ounce) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when performing each of the following repairs: replacement of the A/C evaporator core orifice - replacement of the A/C compressor pressure relief valve - replacement of a refrigerant line - repair of an O-ring leak - repair of a charge port leak 6. Replacement of components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Compressor Oil > Page 1691 Refrigerant Oil: Service and Repair Refrigerant Oil 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 for replacement, 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 replacement part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. 1 Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Compressor Oil > Page 1692 4. For the A/C condenser core, add 30 ml (1 ounce) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when performing each of the following repairs: replacement of the A/C evaporator core orifice - replacement of the A/C compressor pressure relief valve - replacement of a refrigerant line - repair of an O-ring leak - repair of a charge port leak 6. Replacement of components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding Brake Bleeding: Service and Repair Gravity Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. - 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 replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. - When the brake master cylinder has been replaced or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT3 fluid meeting Ford specification ESA-M6C25-A. 2. Bleed the rear disc brake calipers. 1 Place a box end wrench on the RH rear disc brake caliper bleeder screw. 2 Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3 Open the bleeder screw and leave open until clear bubble-free brake fluid flows. Repeat for LH rear disc brake caliper. 3. Tighten the rear disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 1697 4. Bleed the front disc brake calipers. 1 Place a box end wrench on the RH front disc brake caliper bleeder screw. 2 Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3 Open the bleeder screw and leave open until clear bubble-free brake fluid flows. - Repeat for LH front disc brake caliper. 5. Tighten the front disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 1698 Brake Bleeding: Service and Repair Manual Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. - 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 replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 1699 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 7. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat Steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 1700 Brake Bleeding: Service and Repair Master Cylinder Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR IS MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system - 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 replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Disconnect the brake master cylinder outlet tubes. NOTE: When the brake master cylinder has been replaced or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. 2. Install short brake tubes with ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes without air bubbles. 4. Remove the short brake tubes and install the brake outlet tubes. 5. Bleed each brake tube at the brake master cylinder as follows: 1 Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2 Loosen the rearmost brake tube fittings until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 1701 6. While the assistant maintains pressure on the brake pedal, tighten the brake tubes. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 1702 Brake Bleeding: Service and Repair Pressure Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. - 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 replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. - 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. Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. 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. 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 1703 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. 8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 1704 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (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. 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. - 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 replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. - This procedure only needs to be performed if the 4 wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been replaced. - 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. - Performing the NGS program routine drives entrapped air from the otherwise inaccessible lower section of the 4WABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleedings remove the air from the system. - Add recommended brake fluid as necessary throughout the procedure. 1. Connect a clear waste line to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with recommended brake fluid. 2. With the RH rear disc brake caliper bleeder screw open, cycle the brake pedal until no more air is seen in the waste line. 3. Tighten the RH rear disc brake caliper bleeder screw and disconnect the waste line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 1705 4. Repeat steps 1, 2, and 3 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. 5. Connect the NGS DCL cable adapter into the vehicle data link connector (DLC) under the dash and follow the NGS instructions. 6. Repeat the conventional bleed procedure as outlined in Steps 1 through 4. 7. If the brake pedal feels spongy, repeat the NGS service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Page 1706 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect the battery ground cable. WARNING: THE BACKUP POWER SUPPLY ENERGY MUST BE DEPLETED BEFORE ANY AIR BAG COMPONENT REPAIR IS PERFORMED. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the driver side air bag module from the vehicle. WARNING: PLACE THE AIR BAG MODULE ON A BENCH WITH THE TRIM COVER FACING UP TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 4. Connect the air bag simulator to the vehicle harness at the top of the steering column. 5. Remove the passenger side air bag module from the vehicle. WARNING: PLACE THE AIR BAG MODULE ON A BENCH WITH THE DEPLOYMENT DOOR FACING UP TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 6. Connect the air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Reactivation Procedure 1. Disconnect the battery ground cable. WARNING: THE AIR BAG SIMULATORS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. In stall the driver side air bag module. 5. Remove the air bag simulator from the vehicle harness connector at the passenger side air bag module. 6. Install the passenger side air bag module. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 8. Prove out the system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 1711 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Are both air bag sensors connected and mounted to the vehicle? [ ] 2. Is the three-way connector at the base of the steering column connected? [ ] 3. Are the air bag modules or air bag simulators connected? [ ] 4. Is the air bag diagnostic monitor connected? [ ] 5. Is the vehicle battery connected? [ ] Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1717 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1718 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1719 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1720 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1721 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1722 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1723 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1724 Fuse: Electrical Diagrams Generator Mega Fuse (Alternator) - The 175 Amp Mega Fuse (Generator) protects the in-line fuse & generator/voltage regulator. Power Distribution PDB Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1725 Mega Fuse (PDB) - The 175 Amp Mega Fuse (PDB) protects the power distribution box. Power Distribution Mini Fuse Mini Fuse - The 20 Amp Mini Fuse protects the generator/voltage regulator. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1726 Power Distribution Fuse 1 Fuse 1 - protects the following circuits: ^ Powertrain Control Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1727 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Trailer Tow Left Turn Relay ^ Trailer Tow Right Turn Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1728 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ Radio ^ Rear Integrated Control Panel ^ Compact Disc Changer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1729 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Sub-Woofer Power ^ Premium Sound Amplifier Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1730 Power Distribution Fuse 1 Fuse 1 - protects the following circuits: ^ Flasher Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1731 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Instrument Cluster ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1732 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ Cigar Lighter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1733 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ Park Lamp Relay ^ Headlamp Relay ^ Autolamp Module ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1734 ^ Power Mirror Switch Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1735 ^ Speed Control Servo/Amplifier Assembly ^ Heater-A/C Control Assembly ^ Blend Door Actuator ^ Electronic Variable Orifice Module Power Distribution Fuse 6 Fuse 6 - protects the following circuits: ^ Shift Lock Actuator Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1736 ^ Generic Electronic Module ^ 4 Wheel Air Suspension Module ^ Compass Sensor ^ Steering Wheel Rotation Sensor ^ Heated Grid Relay ^ Overhead Trip Computer Module Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1737 Fuse 7 Fuse 7 - protects the following circuits: ^ Auxiliary A/C Relay ^ Console Blower Motor Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Radio ^ Main Light Switch ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1738 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1739 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Washer Pump Relay ^ Wiper Run/Park Relay ^ Wiper High/Low Relay ^ Windshield Wiper Motor ^ Rear Wiper Pump Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1740 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: ^ Data Link Connector Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1741 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Brake Pedal Position Switch ^ Brake Pressure Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1742 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: ^ Battery Saver Relay ^ Interior Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1743 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Generic Electronic Module ^ Passive Anti-Theft System Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1744 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Instrument Cluster (Without Daytime Running Lamps) ^ Daytime Running Lamps Module ^ High Beam Headlamps Power Source Power is Supplied Through Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1745 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Heated Backlight Switch ^ Left Power/Heated Signal Mirror ^ Right Power/Heated Signal Mirror Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1746 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Main Light Switch ^ Generic Electronic Module ^ Instrument Illumination Power Source Power is Supplied Through Main Light Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1747 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: ^ Instrument Cluster ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1748 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: ^ 4 Wheel Air Suspension ^ Generic Electronic Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1749 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Junction Box Fuse/Relay Panel Fuse 20 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1750 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1751 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ 4X4 Center Axle Disconnect Solenoid ^ Function Selector Switch ^ Rear Integrated Control Panel ^ Recirculation Vacuum Solenoid Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1752 ^ Auxiliary A/C Mode Actuator ^ Auxiliary A/C Control Module Power Distribution Fuse 24 Fuse 24 - protects the following circuits: ^ Function Selector Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1753 Power Distribution Fuse 25 Fuse 25 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System (4WABS) Module ^ 4WABS Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1754 Power Distribution Fuse 26 Fuse 26 - protects the following circuits: ^ Daytime Running Lamps Module ^ Right Headlamp Power Source Power is Supplied Through Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1755 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: ^ Main Light Switch ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1756 Power Distribution Fuse 28 Fuse 28 - protects the following circuits: ^ Left Headlamp Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1757 Power Distribution Fuse 29 Fuse 29 - protects the following circuits: ^ Autolamp Module ^ Instrument Cluster ^ Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1758 Power Distribution Fuse 30 Fuse 30 - protects the following circuits: ^ Radio Noise Capacitor ^ Ignition Coil ^ PCM Power Diode ^ Coil On Plugs ^ Passive Anti-Theft System Control Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1759 Power Distribution Fuse 1 Fuse 1 - protects the following circuits: ^ Trailer Tow Running Lamp Relay ^ Trailer Tow Backup Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1760 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1761 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ All Unlock Relay ^ All Lock Relay ^ Driver's Unlock Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1762 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ Air Suspension Service Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1763 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Horn Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1764 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: ^ Radio ^ Premium Sound Amplifier ^ Compact Disc Changer ^ Rear Integrated Control Panel ^ Engine Fuse Module Fuse 3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1765 ^ Engine Fuse Module Fuse 5 ^ Sub-Woofer Power Power Distribution Fuse 7 Fuse 7 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1766 ^ Main Light Switch ^ Park Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1767 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Main Light Switch ^ Headlamp Relay ^ Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1768 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1769 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: ^ Daytime Running Lamps Module ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1770 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: ^ Instrument Panel Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1771 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Console Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1772 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: ^ Rear Wiper Up Motor Relay ^ Rear Wiper Down Motor Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1773 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Auxiliary A/C Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1774 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1775 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Air Suspension Solid State Compressor Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1776 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ Engine Fuse Module Fuse 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1777 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Shift On The Fly Relay ^ Transfer Case Shift Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1778 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1779 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: ^ Fuel Pump Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1780 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: ^ Ignition Switch (B4 & B5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1781 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1782 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: ^ Ignition Switch (B1 & B3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1783 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1784 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: ^ Junction Box Fuse/Relay Panel Battery Feed Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1785 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1786 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: ^ Instrument Panel Blower Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1787 Power Distribution Fuse 24 Fuse 24 - protects the following circuits: ^ PCM Power Relay ^ Engine Fuse Module Fuse 1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1788 Power Distribution Fuse 25 Fuse 25 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1789 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1790 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Heated Grid Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1791 Power Distribution Fuse 28 Fuse 28 - protects the following circuits: ^ Trailer Electronic Brake Controller Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1792 Power Distribution Fuse 29 Fuse 29 - protects the following circuits: ^ Flip Window Relay ^ Hybrid Cooling Fan Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1793 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Engine Fuse Module Fuse Block: Locations Engine Fuse Module Engine View The Engine Fuse Module is located near the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Engine Fuse Module > Page 1798 Fuse Block: Locations Junction Box/Fuse Relay Panel Junction Box Fuse/Relay Panel (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Engine Fuse Module > Page 1799 Instrument Panel View The Junction Box/Fuse Relay Panel is located under left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1802 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1803 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1804 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1805 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1806 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1807 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1808 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1809 Fuse Block: Connector Views Junction Box/Fuse Panel (C243) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1810 Junction Box/Fuse Panel (C242) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1811 Fuse Block: Electrical Diagrams Engine Mini- Fuse Block Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1812 Junction Box Fuse/Relay Panel (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1813 Junction Box Fuse/Relay Panel (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1814 Power Distribution Box Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1815 Primary Battery Fuses Fuse 1 - Trailer Backup and Running Lamp Relays Fuse 1 - protects the following circuits: ^ Trailer Tow Running Lamp Relay ^ Trailer Tow Backup Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1816 Power Distribution Fuse 2 - Air Bag Diagnostic Monitor Fuse 2 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1817 Power Distribution Fuse 3 - All Unlock/Lock Relays, Drivers' Unlock Relay Fuse 3 - protects the following circuits: ^ All Unlock Relay ^ All Lock Relay ^ Driver's Unlock Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1818 Power Distribution Fuse 4 - Air Suspension Service Switch Fuse 4 - protects the following circuits: ^ Air Suspension Service Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1819 Power Distribution Fuse 5 - Horn Relay Fuse 5 - protects the following circuits: ^ Horn Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1820 Power Distribution Fuse 6 - Var. Sound Sys. Components, Eng. Fuse Mdl Fuses 3 & 5 Fuse 6 - protects the following circuits: ^ Radio ^ Premium Sound Amplifier ^ Compact Disc Changer ^ Rear Integrated Control Panel ^ Engine Fuse Module Fuse 3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1821 ^ Engine Fuse Module Fuse 5 ^ Sub-Woofer Power Power Distribution Fuse 7 - Main Light Switch, Park Lamp Relay Fuse 7 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1822 ^ Main Light Switch ^ Park Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1823 Power Distribution Fuse 8 - Main Light Switch, Headlamp Relay, Multi-function Sw Fuse 8 - protects the following circuits: ^ Main Light Switch ^ Headlamp Relay ^ Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1824 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1825 Power Distribution Fuse 9 - DRL Module, Fog Lamp Relay Fuse 9 - protects the following circuits: ^ Daytime Running Lamps Module ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1826 Power Distribution Fuse 10 - Instrument Panel Aux. Power Socket Fuse 10 - protects the following circuits: ^ Instrument Panel Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1827 Power Distribution Fuse 11 - Console Aux. Power Socket Fuse 11 - protects the following circuits: ^ Console Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1828 Power Distribution Fuse 12 - Rear Wiper Up And Down Motor Relays Fuse 12 - protects the following circuits: ^ Rear Wiper Up Motor Relay ^ Rear Wiper Down Motor Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1829 Power Distribution Fuse 13 - Auxiliary A/C Relay Fuse 13 - protects the following circuits: ^ Auxiliary A/C Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1830 Power Distribution Fuse 14 - 4 Wheel Anti-Lock Brake System Module Fuse 14 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1831 Power Distribution Fuse 15 - Air Suspension Solid State Compressor Relay Fuse 15 - protects the following circuits: ^ Air Suspension Solid State Compressor Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1832 Power Distribution Fuse 16 - Trailer Tow Bttry Charge Relay, Eng Fuse Module Fuse2 Fuse 16 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ Engine Fuse Module Fuse 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1833 Power Distribution Fuse 17 - Shift-On-The-Fly Relay, Tranfer Case Shift Relay Fuse 17 - protects the following circuits: ^ Shift On The Fly Relay ^ Transfer Case Shift Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1834 Power Distribution Fuse 18 - Power Seat Control Switch Fuse 18 - protects the following circuits: ^ Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1835 Power Distribution Fuse 19 - Fuel Pump Relay Fuse 19 - protects the following circuits: ^ Fuel Pump Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1836 Power Distribution Fuse 20 - Ignition Switch Fuse 20 - protects the following circuits: ^ Ignition Switch (B4 & B5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1837 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1838 Power Distribution Fuse 21 - Ignition Switch Fuse 21 - protects the following circuits: ^ Ignition Switch (B1 & B3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1839 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1840 Power Distribution Fuse 22 - Junction Box Fuse/Relay Panel Battery Feed Fuse 22 - protects the following circuits: ^ Junction Box Fuse/Relay Panel Battery Feed Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1841 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1842 Power Distribution Fuse 23 - Instrument Panel Blower Relay Fuse 23 - protects the following circuits: ^ Instrument Panel Blower Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1843 Power Distribution Fuse 24 - PCM Power Relay, Engine Fuse Module Fuse 1 Fuse 24 - protects the following circuits: ^ PCM Power Relay ^ Engine Fuse Module Fuse 1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1844 Power Distribution Fuse 25 - Junction Box Fuse/Relay Panel, Accessory Delay Relay Fuse 25 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1845 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1846 Power Distribution Fuse 27 - Junction Box Fuse/Relay Panel, Heated Grid Relay Fuse 27 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Heated Grid Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1847 Power Distribution Fuse 28 - Trailer Electronic Brake Controller Fuse 28 - protects the following circuits: ^ Trailer Electronic Brake Controller Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1848 Power Distribution Fuse 29 - Flip Window Relay, Hybrid Cooling Fan Relay Fuse 29 - protects the following circuits: ^ Flip Window Relay ^ Hybrid Cooling Fan Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1849 Power Distribution Fuse 1 - Flasher Relay Fuse 1 - protects the following circuits: ^ Flasher Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1850 Power Distribution Fuse 2 - Instrument Cluster, OH Trip Computer Fuse 2 - protects the following circuits: ^ Instrument Cluster ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1851 Power Distribution Fuse 3 - Cigar Lighter Fuse 3 - protects the following circuits: ^ Cigar Lighter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1852 Power Distribution Fuse 4 - Park & Hdlp Relays, Autolamp & RAP Mdl, Pwr Mirror Sw. Fuse 4 - protects the following circuits: ^ Park Lamp Relay ^ Headlamp Relay ^ Autolamp Module ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1853 ^ Power Mirror Switch Power Distribution Fuse 5 - TRS, DRL Mdl, Spd Ctrl Servo/Amp Assy, HVAC Ctrl Assy Fuse 5 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1854 ^ Speed Control Servo/Amplifier Assembly ^ Heater-A/C Control Assembly ^ Blend Door Actuator ^ Electronic Variable Orifice Module Power Distribution Fuse 6 - Shift Lock, GEM, Air Susp. Mdl, OH Trip Cmptr, Compass Fuse 6 - protects the following circuits: ^ Shift Lock Actuator Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1855 ^ Generic Electronic Module ^ 4 Wheel Air Suspension Module ^ Compass Sensor ^ Steering Wheel Rotation Sensor ^ Heated Grid Relay ^ Overhead Trip Computer Module Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1856 Fuse 7 - Aux. A/C Relay, Blower Motor Fuse 7 - protects the following circuits: ^ Auxiliary A/C Relay ^ Console Blower Motor Power Distribution Fuse 8 - Radio, Main Light Switch, RAP Module Fuse 8 - protects the following circuits: ^ Radio ^ Main Light Switch ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1857 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1858 Power Distribution Fuse 11 - Washer Pump, Wiper Run/Park Hi/Lo Relays, Wiper Motor Fuse 11 - protects the following circuits: ^ Washer Pump Relay ^ Wiper Run/Park Relay ^ Wiper High/Low Relay ^ Windshield Wiper Motor ^ Rear Wiper Pump Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1859 Power Distribution Fuse 12 - Data Link Connector Fuse 12 - protects the following circuits: ^ Data Link Connector Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1860 Power Distribution Fuse 13 - Brake Pedal Position and Brake Pressure Switches Fuse 13 - protects the following circuits: ^ Brake Pedal Position Switch ^ Brake Pressure Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1861 Power Distribution Fuse 14 - Battery Saver and Interior Lamp Relays Fuse 14 - protects the following circuits: ^ Battery Saver Relay ^ Interior Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1862 Power Distribution Fuse 15 - GEM and RAP Modules Fuse 15 - protects the following circuits: ^ Generic Electronic Module ^ Passive Anti-Theft System Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1863 Power Distribution Fuse 16 - Inst. Cluster, DRL Module, High Beam Headlamps Fuse 16 - protects the following circuits: ^ Instrument Cluster (Without Daytime Running Lamps) ^ Daytime Running Lamps Module ^ High Beam Headlamps Power Source Power is Supplied Through Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1864 Power Distribution Fuse 17 - Htd Backlight Sw, Left & Right Pwr/Htd Signal Mirrors Fuse 17 - protects the following circuits: ^ Heated Backlight Switch ^ Left Power/Heated Signal Mirror ^ Right Power/Heated Signal Mirror Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1865 Power Distribution Fuse 18 - Main Light Sw, GEM, Instr. Illumination Fuse 18 - protects the following circuits: ^ Main Light Switch ^ Generic Electronic Module ^ Instrument Illumination Power Source Power is Supplied Through Main Light Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1866 Power Distribution Fuse 19 - Instrument Cluster, Air Bag Diagnostic Monitor Fuse 19 - protects the following circuits: ^ Instrument Cluster ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1867 Power Distribution Fuse 20 - 4 Wheel Air Suspension, GEM Fuse 20 - protects the following circuits: ^ 4 Wheel Air Suspension ^ Generic Electronic Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1868 Power Distribution Fuse 21 - Digital Trans. Range Snsr, JB Fuse/Relay Pnl Fuse 20 Fuse 21 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Junction Box Fuse/Relay Panel Fuse 20 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1869 Power Distribution Fuse 22 - Air Bag Diagnostic Monitor Fuse 22 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1870 Power Distribution Fuse 23 - Tow Btty Chg Relay, 4X4 Ctr Axle Disc, Func Selector Fuse 23 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ 4X4 Center Axle Disconnect Solenoid ^ Function Selector Switch ^ Rear Integrated Control Panel ^ Recirculation Vacuum Solenoid Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1871 ^ Auxiliary A/C Mode Actuator ^ Auxiliary A/C Control Module Power Distribution Fuse 24 - Function Selector Switch Fuse 24 - protects the following circuits: ^ Function Selector Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1872 Power Distribution Fuse 25 - 4WABS Module and 4WABS Relay Fuse 25 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System (4WABS) Module ^ 4WABS Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1873 Power Distribution Fuse 26 - DRL Module and Right Headlamp Fuse 26 - protects the following circuits: ^ Daytime Running Lamps Module ^ Right Headlamp Power Source Power is Supplied Through Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1874 Power Distribution Fuse 27 - Main Light Switch and Fog Lamp Relay Fuse 27 - protects the following circuits: ^ Main Light Switch ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1875 Power Distribution Fuse 28 - Left Headlamp Fuse 28 - protects the following circuits: ^ Left Headlamp Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1876 Power Distribution Fuse 29 - Autolamp Module, Instrument Cluster, Trans Ctrl Sw Fuse 29 - protects the following circuits: ^ Autolamp Module ^ Instrument Cluster ^ Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1877 Power Distribution Fuse 30 - Radio Noise Cap., Ignition Coil, PCM Pwr Diode... Fuse 30 - protects the following circuits: ^ Radio Noise Capacitor ^ Ignition Coil ^ PCM Power Diode ^ Coil On Plugs ^ Passive Anti-Theft System Control Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1878 Power Distribution Fuse 1 - Powertrain Control Module Fuse 1 - protects the following circuits: ^ Powertrain Control Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1879 Power Distribution Fuse 2 - Trailer Tow Left and Right Turn Relays Fuse 2 - protects the following circuits: ^ Trailer Tow Left Turn Relay ^ Trailer Tow Right Turn Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1880 Power Distribution Fuse 3 - Radio, Rear Integrated Control Panel, CD Changer Fuse 3 - protects the following circuits: ^ Radio ^ Rear Integrated Control Panel ^ Compact Disc Changer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1881 Power Distribution Fuse 5 - Subwoofer Power, Premium Sound Amplifier Fuse 5 - protects the following circuits: ^ Sub-Woofer Power ^ Premium Sound Amplifier Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1882 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Blower/Flasher Relay Block Relay Box: Locations Blower/Flasher Relay Block Instrument Panel View The Blower/Flasher Relay Block is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 1887 Relay Box: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 1888 Relay Box: Locations Regular Production Option Relay Block Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Blower/Flasher Relay Block Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 1891 Lock Relays Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 1892 Power Distribution Relay Box Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 1893 RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair NOTE : The RESET procedure is found ONLY in the Owners Manual. For most Ford vehicles, the RESET procedure mainly includes just pressing the RESET button for five(5) seconds but it is recommended that the Owners Manual is consulted first. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation WARNING: ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. Jacking Points - Front, 4x4 The jacking point is a raised boss located on the front suspension lower arm. Jacking Points - Front, 4x2 The jacking point is a bracket welded to the frame located behind the front tire and wheel assembly. Jacking Points - Rear CAUTION: Never use the differential housing as a lifting point. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 1905 The rear jacking points are located on the rear axle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Lifting Vehicle Lifting: Service and Repair Lifting WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Lifting Points-Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Lifting Points - Drive On Hoist The vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Lifting > Page 1908 Vehicle Lifting: Service and Repair Lifting, Jacking and Hoisting WARNING: ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. Jacking Points - Front, 4x4 The jacking point is a raised boss located on the front suspension lower arm. Jacking Points - Front, 4x2 The jacking point is a bracket welded to the frame located behind the front tire and wheel assembly. Jacking Points - Rear Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Lifting > Page 1909 CAUTION: Never use the differential housing as a lifting point. The rear jacking points are located on the rear axle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Lifting > Page 1910 Vehicle Lifting: Service and Repair Vehicle Lifting and Jacking WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Lifting Points-Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Lifting Points - Drive On Hoist The vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications Spare Tire: Specifications TORQUE SPECIFICATIONS Spare Tire Carrier Bolts ............................................................................................................................................................. 23-32 Nm (17-23 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications > Page 1915 Spare Tire: Service and Repair REMOVAL 1. Lower the spare tire. (1) Insert the drive end of the jack handle through the opening left of the license plate. (2) Turn the jack handle until slack is present in the cable. 2. Remove the spare tire. (1) Slide the retainer through the center of the spare tire assembly. (2) Remove the spare tire assembly. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Remove the spare tire carrier. (1) Remove the two bolts. (2) Turn the spare tire carrier to disengage the spare tire carrier from the tabs and remove the spare tire carrier. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications > Page 1916 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1921 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1922 Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1923 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1924 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1925 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1926 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1927 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1928 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1929 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1930 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1931 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1932 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1933 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1934 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1935 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1936 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1937 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1938 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1939 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1940 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1941 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1942 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1943 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1944 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1945 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1946 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1947 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1948 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1949 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1950 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1951 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1952 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1953 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1954 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1955 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1956 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1957 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1958 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1959 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1960 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1961 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1962 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1963 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1964 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1965 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1966 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1967 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1968 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1969 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1970 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1971 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1972 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1973 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1974 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1975 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1976 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1977 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1978 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1979 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1980 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1981 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1982 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1983 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1984 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1985 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1986 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1987 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1988 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1989 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1990 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1991 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1992 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1993 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1994 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1995 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1996 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1997 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1998 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1999 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2001 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2002 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2003 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2004 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2005 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2006 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2007 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2008 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2009 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2010 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2011 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2012 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2013 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2014 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2015 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 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. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2016 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 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. 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 the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2017 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2018 Wheels: Specifications GENERAL SPECIFICATIONS Cast Aluminum .................................................................................................................................... ................................................................ 17 x 7.5J Steel .................................................................... .................................................................................................................................................... 16 x 7J Styled Aluminum ............................................................................................................................. ....................................................................... 16 x 7J Styled Argent Steel ......................................... ........................................................................................................................................................ 16 x 7J Wheel Offset ................................................................................................................................ ........................................................................... 14 mm Wheel Rim Runout (Radial Or Lateral) ........................................................................................................................................... 1.12 mm (0.044 inch) Maximum Balance Weight [a] .......................................................................................... ............................................................................. 170 g (6 oz.) [a] Total Of Inner And Outer Wheel Flanges Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service Precautions > Technician Safety Information Wheels: Technician Safety Information WARNING: NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, FOR EXAMPLE, WHEN CHANGING A TIRE. THE WHEEL RESTING ON THE GROUND COULD CAUSE THE VEHICLE TO MOVE. THE TIRE AND WHEEL MUST ALWAYS BE PROPERLY MATCHED. DO NOT MOUNT A 16-INCH TIRE ON A 16.5-INCH WHEEL. FAILURE TO ADHERE TO THESE INSTRUCTIONS COULD RESULT IN AN EXPLOSIVE SEPARATION AND CAUSE SERIOUS BODILY INJURY OR DEATH. IT IS VERY IMPORTANT TO DETERMINE THE SIZE OF EACH COMPONENT BEFORE ANY ASSEMBLY OPERATIONS COMMENCE. DO NOT MOUNT A 16.5-INCH TIRE ON A 16-INCH WHEEL. THE TIRE CAN COME OFF WITHOUT WARNING. AFTERMARKET AEROSOL TIRE SEALANTS ARE EXTREMELY FLAMMABLE. ALWAYS QUESTION CUSTOMER TO MAKE SURE THESE PRODUCTS HAVE NOT BEEN USED. ALWAYS WEAR SAFETY GOGGLES OR A FACE SHIELD WHEN PERFORMING ANY WORK WITH TIRE AND WHEEL ASSEMBLIES. CAUTION: Reduce the air pressure as much as possible by pushing the valve core plunger in prior to removing the valve core. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service Precautions > Technician Safety Information > Page 2021 Wheels: Vehicle Damage Warnings WARNING: USE ONLY WHEELS AND LUG NUTS THAT HAVE BEEN DESIGNED FOR 1997 FORD TRUCKS. AFTERMARKET WHEELS OR LUG NUTS MAY NOT FIT OR FUNCTION PROPERLY AND CO=D HOT YOU OR DAMAGE THE VEHICLE. RETIGHTEN AT 800 KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. CAUTION: Do not clean aluminum wheels with steel wool, abrasive-type cleaners or strong detergents. Use Custom Bright Metal Cleaner 8A-19522-A or equivalent meeting Ford specification ESR-M5B194-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service Precautions > Page 2022 Wheels: Description and Operation WARNING: DO NOT MIX DIFFERENT TYPES OF TIRES ON THE SAME VEHICLE SUCH AS RADIAL, BIAS, OR BIAS-BELTED TIRES EXCEPT IN EMERGENCIES (TEMPORARY SPARE USAGE), BECAUSE VEHICLE HANDLING MAY BE SERIOUSLY AFFECTED AND MAY RESULT IN LOSS OF CONTROL. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures. Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase tire wear. Replacement tires should follow the recommended: - Tresses. - Speed rating. - Load range. - Radial construction type. Use of any other tire size or type may seriously affect: - Ride. - Handling. - Speedometer/odometer calibration. - Vehicle ground clearance. - Tire clearance between the body and chassis. - Wheel bearing life. - Brake cooling. Wheels need to be replaced when: - Bent. - Dented. - Heavily rusted. - Leaking. - They have elongated wheel hub bolt holes. - They have excessive lateral or radial runout. A two-piece lug nut is used, containing the nut and a washer. Wheel and tire assemblies are attached by five noncentering lug nuts. When balancing wheels and tires, use T-type balancing weights. The spare tire is mounted under the frame. The valve stem should he on the top side of the tire to reduce the possibility of accidental valve stem air leakage. To equalize tire wear, the tires should be rotated periodically. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Wheels: Symptom Related Diagnostic Procedures Wheels And Tires Symptom Chart, Part 1 Of 4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2025 Wheels And Tires Symptom Chart, Part 2 Of 4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2026 Wheels And Tires Symptom Chart, Part 3 Of 4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2027 Wheels And Tires Symptom Chart, Part 4 Of 4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2028 Wheels: Component Tests and General Diagnostics Leaks 1. Replace or repair any wheel that leaks air. CAUTION: Do not attempt to repair aluminum wheels that leak air. If repairs are made to the wheel, the structural integrity of the wheel can be lost. Replace any aluminum wheel that leaks air. Runout TEST DESCRIPTION Excessive radial and lateral runout of a wheel and tire assembly can cause roughness, vibration, wheel tramp, tire wear, and steering wheel tremor. Before checking runout and to avoid false readings caused by temporary flat spots in the tires, check runout only after the vehicle has been driven far enough to warm tires. The extent of the runout is measured with Radial Runout Gauge. All measurements are made on the vehicle with the tires inflated to recommended inflation pressures and with the front wheel bearings adjusted to specifications. TIRE RUNOUT Use Radial Runout Gauge to measure (A) radial runout of the tire at the center and outside ribs of the tread face. Mark the high points of radial runout for future reference. Radial runout should not exceed specifications. WHEEL RUNOUT Measure (B) radial and (C) lateral wheel runout at the positions shown. Runout should not exceed specifications. Wheel Centering 0-Ring Seal The front hub and rear axle wheel pilots are fitted with rubber O-rings which help center the wheels. Remove the O-ring and clean the machined groove and clean and lubricate the O-ring if required. Replace the O-ring if damaged. O-rings should be pulled on (not pushed) so that the yellow paint identification stripe is visible after installation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Page 2029 Wheels: Service and Repair REMOVAL 1. Loosen the lug nuts. (1) Remove the center cap. (2) With the weight of the vehicle on the wheels, loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. 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 MA Y RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. (1) Remove the lug nuts. (2) Remove the wheel and tire assembly. INSTALLATION 1. Clean the wheel hub mounting surface. WARNING: WHEN A WHEEL IS INSTALLED, ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL PRESENT ON THE MOUNTING SURFACES OF THE WHEEL OR THE SURFACE OF THE WHEEL HUB, BRAKE DRUM OR BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL TO METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUTS TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. 2. Install the tire and wheel assembly. (1) Inspect the wheel centering O-ring. Replace if damaged. (2) Position the tire and wheel assembly. (3) Install the lug nuts, hand-tight, then lower the vehicle NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Page 2030 3. Tighten the lug nuts in sequence. 4. Install the center cap. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2035 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2036 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2037 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2038 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2039 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2040 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2041 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2042 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2043 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2044 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2045 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2046 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2047 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2048 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2049 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2050 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2051 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2052 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2053 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2054 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2055 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2056 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2057 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2058 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2059 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2060 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2061 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2062 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2063 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2064 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2065 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2066 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2067 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2068 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2069 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2070 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2071 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2072 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2073 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2074 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2075 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2076 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2077 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2078 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2079 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2080 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2081 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2082 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2083 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2084 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2085 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2086 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2087 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2088 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2089 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2090 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2091 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2092 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2093 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2094 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2095 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2096 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2097 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2098 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2099 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2100 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2101 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2102 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2103 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2104 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2105 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2106 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2107 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2108 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2109 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2110 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2111 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2112 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2113 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2114 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2115 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2116 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2117 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2118 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2119 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2120 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2121 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2122 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2123 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2124 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2125 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2126 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2127 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 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. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2128 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 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. 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 the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2129 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 2130 Wheel Bearing: Specifications Rear Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front REMOVAL NOTE: The wheel bearing and hub are replaced as an assembly. 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the wheel and tire assembly. 3. Remove the front disc brake rotor. 4. Remove the front wheel hub nut. (1) Remove the cotter pin. (2) Remove the retainer. (3) Remove the nut. 5. Remove the front disc brake rotor shield. (1) Remove the bolts. (2) Remove the front disc brake rotor shield. 6. Remove the front brake anti-lock sensor. (1) Remove the bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2133 (2) Remove the front brake anti-lock sensor. 7. Remove the wheel hub. (1) Remove the bolts. (2) Push the CV joint inboard. Remove the wheel hub. CAUTION: Do not over extend CV joint and boots when removing the hub and bearing assembly. NOTE: The CV joint is a slip fit into the wheel hub and bearing. A puller will not normally be required. 8. Remove the seal. INSTALLATION 1. Install the seal. - Use Knuckle Seal Replacer, Threaded Drawbar and Bearing Cup Replacer to install the seal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2134 2. Install the wheel hub. (1) Position the wheel hub on the front wheel driveshaft and joint and into the front wheel knuckle. (2) Install the bolts. 3. Install the front brake anti-lock sensor. (1) Install the front brake anti-lock sensor into the wheel hub. (2) Install the bolt. 4. Install the front disc brake rotor shield and front axle hub nut. (1) Position the front disc brake rotor shield. (2) Install the bolts. (3) Install the front axle hub nut. (4) Install the retainer. (5) Install cotter pin. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2135 5. Install the front disc brake rotor. 6. Install the tire and wheel assembly. (1) Position the tire and wheel assembly. (2) Install the lug nuts. (3) Tighten the lug nuts in the sequence indicated. (4) Install the center cap. WARNING: WHEN THE WHEEL IS INSTALLED, ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL THAT MAY BE PRESENT ON THE MOUNTING SURFACES OF THE WHEELS OR THE SURFACES OF THE WHEEL HUB, BRAKE DRUM OR BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUT TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. RETIGHTEN AT 800 KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. 7. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2136 Wheel Bearing: Service and Repair Rear 8.8 Inch Ring Gear Special Tools Special Tools REMOVAL 1. Remove the axle shaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2137 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with debris. Use Impact Slide Hammer and Axle Wheel Bearing Puller to remove the rear wheel bearing and inner wheel bearing oil seal. INSTALLATION 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2Cl92-A. 2. Use Axle Wheel Bearing Replacer with Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-l-C or equivalent meeting Ford specification ESA-MlC75-B. 4. Use Axle Seal Replacer with Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shafts. 9.75 Inch Ring Gear Models With Rear Disc Brakes Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2138 Special Tools REMOVAL 1. Remove the axle shaft. 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with debris. Use the Impact Slide Hammer and the Axle Bearing Remover to remove the rear wheel bearing and inner wheel bearing oil seal. INSTALLATION 1. Lubricate the new rear axle bearing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2139 - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use the Axle Wheel Bearing Replacer with the Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Use the Axle Seal Replacer with the Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Hub Nut 255-345 Nm (188-254 ft.lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose Technical Service Bulletin # 98S14 Date: 980601 Recall - Wheel Lug Nuts Loose 98S14 SAFETY RECALL All 1997 and Certain 1998 Model Year F-150/250 (under 8,500 lbs.) Series Trucks, all 1997 and Certain 1998 Model Year Expeditions and Certain 1998 Navigator Vehicles - Wheel Attachment ^ Original - June, 1998 ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter ^ Questions and Answer Sheet ^ Supplement # 1 ^ Parts Availability - July, 1998 ^ parts Fax letter - July, 1998 ^ Supplement # 2 ^ Parts Availability - September, 1998 ^ Parts Fax Letter - September, 1998 ^ Supplement # 3 ^ Parts Availability - November, 1998 ^ Important Recall/Service Program Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2152 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2153 Attachment I - Administrative Information OASIS OASIS will not be activated until the second owner mailing begins informing owners of lug nut availability. Vehicle involvement for the interim service action can be determined by using OASIS to confirm the vehicle build date. PLEASE NOTE: Before delivery of a new vehicle to a customer, you are required to perform this tightening procedure to all four wheels. Federal law requires that dealers conduct this tightening procedure prior to delivery to a buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1'100 per vehicle. PROMPTLY CORRECT Affected vehicles which are brought to your dealership. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. WARRANTY AND POLICY MANUAL See Sections 5 and 6 of the ACESII Manual. REFUNDS See ACESII Manual, Section 3. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2154 PARTS REQUIREMENTS Initial supply of revised finish lug nuts (permanent corrective action) is limited. Dealers are requested to tighten current lug nuts per the attached procedure in the interim. Parts will be available in the third (3rd) quarter of 1998. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information TWO-PIECE LUG NUT REPLACEMENT INTERIM SERVICE ACTION - LUG NUTS SERVICE PROCEDURE 1. Remove center cap (hubcap) from each wheel. 2. Tighten each lug nut in sequence shown in figure 1 to verify that the nut is at 100 lb-ft. A torque wrench should be used to ensure proper torque. 3. Tighten each lug nut again in sequence, an additional 1/8 to 1/4 turn. 4. Install center cap (hubcap) on each wheel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2155 TWO-PIECE LUG NUT REPLACEMENT AFFECTED VEHICLES: 1997-1998 EXPEDITION/NAVIGATOR AND F-150/250 SERVICE PROCEDURE The following service procedure must be performed on all four (4) wheels. 1. Remove center caps from wheels. 2. Loosen lug nuts on all four (4) wheels. 3. Raise vehicle on hoist. 4. Remove all lug nuts. 5. Remove tire and wheel assemblies. 6. With wire brush, clean back of wheel (brake rotor/drum mating surface) of any foreign material. 7. Inspect all wheel stud holes for damage (cracked or distorted).If cracked or distorted (if a penny can fit through the stud hole), the wheel must be replaced. 8. Inspect all studs. Replace if damaged. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2156 9. Remove and discard hub 0-ring and any remaining pieces from the front and rear hubs. 10. Install wheel and tire assemblies. NOTE: Do not tighten lug nuts to final torque at this time. 11. Install new lug nuts and tighten enough to securely mate wheel against rotor/drum. 12. Lower vehicle and tighten lug nuts in sequence shown to 136 Nm (100 lb-ft). See Figure 4. 13. Install center caps. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2157 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2158 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2159 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2160 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2161 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2162 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2163 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2164 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > NHTSA98V095000 > May > 98 > Recall 98V095000: Lug Nut Replacement Wheel Fastener: Recalls Recall 98V095000: Lug Nut Replacement Year: 1997, 1998 Make: LINCOLN TRUCK, FORD TRUCK Model: NAVIGATOR, EXPEDITION, F150, F250 Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 1520000 Summary: Vehicle Description: Multi-purpose vehicles and light duty pickup trucks. The lug nuts on these vehicles may not create sufficient clamp load allowing wheel movement in relation to the hub/rotor mounting surface. This can result in the loosening of lug nuts, stud fatigue failure, and the potential for a wheel separation from the vehicle, increasing the risk of a vehicle crash. Dealers will inspect the wheel studs and replace the wheel lug nuts. Owner notification is expected to begin July 20, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > NHTSA98V095000 > May > 98 > Recall 98V095000: Lug Nut Defect Wheel Fastener: Recalls Recall 98V095000: Lug Nut Defect NHTSA CAMPAIGN ID Number: 98V095000 Component: WHEELS: LUGS: NUTS: BOLTS Manufacturer: FORD MOTOR COMPANY Year: 1998 Make: FORD TRUCK Model: EXPEDITION Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 1520000 Summary: Vehicle Description: Multi-purpose vehicles and light duty pickup trucks. The lug nuts on these vehicles may not create sufficient clamp load allowing wheel movement in relation to the hub/rotor mounting surface. This can result in the loosening of lug nuts, stud fatigue failure, and the potential for a wheel separation from the vehicle, increasing the risk of a vehicle crash. Owners of these vehicles will be receiving two notifications. The first notification, which began in May 1998, will provide an interim repair procedure until parts become available. This interim procedure can be completed by owners or their dealers. It specifies that the lug nut torque must be verified to be 100 lbs. Then the lug nuts need to be tightened an additional 1/8 to 1/4 turn more. There will be a second owner notification, which is expected to begin July 20, 1998, under which dealers will inspect the wheel studs and replace the wheel lug nuts. Owners will be receiving two notifications. The first notification, which began in May 1998, will provide an interim repair procedure. There will be a second owner notification, which is expected to begin July 20, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose Technical Service Bulletin # 98S14 Date: 980601 Recall - Wheel Lug Nuts Loose 98S14 SAFETY RECALL All 1997 and Certain 1998 Model Year F-150/250 (under 8,500 lbs.) Series Trucks, all 1997 and Certain 1998 Model Year Expeditions and Certain 1998 Navigator Vehicles - Wheel Attachment ^ Original - June, 1998 ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter ^ Questions and Answer Sheet ^ Supplement # 1 ^ Parts Availability - July, 1998 ^ parts Fax letter - July, 1998 ^ Supplement # 2 ^ Parts Availability - September, 1998 ^ Parts Fax Letter - September, 1998 ^ Supplement # 3 ^ Parts Availability - November, 1998 ^ Important Recall/Service Program Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2178 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2179 Attachment I - Administrative Information OASIS OASIS will not be activated until the second owner mailing begins informing owners of lug nut availability. Vehicle involvement for the interim service action can be determined by using OASIS to confirm the vehicle build date. PLEASE NOTE: Before delivery of a new vehicle to a customer, you are required to perform this tightening procedure to all four wheels. Federal law requires that dealers conduct this tightening procedure prior to delivery to a buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1'100 per vehicle. PROMPTLY CORRECT Affected vehicles which are brought to your dealership. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. WARRANTY AND POLICY MANUAL See Sections 5 and 6 of the ACESII Manual. REFUNDS See ACESII Manual, Section 3. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2180 PARTS REQUIREMENTS Initial supply of revised finish lug nuts (permanent corrective action) is limited. Dealers are requested to tighten current lug nuts per the attached procedure in the interim. Parts will be available in the third (3rd) quarter of 1998. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information TWO-PIECE LUG NUT REPLACEMENT INTERIM SERVICE ACTION - LUG NUTS SERVICE PROCEDURE 1. Remove center cap (hubcap) from each wheel. 2. Tighten each lug nut in sequence shown in figure 1 to verify that the nut is at 100 lb-ft. A torque wrench should be used to ensure proper torque. 3. Tighten each lug nut again in sequence, an additional 1/8 to 1/4 turn. 4. Install center cap (hubcap) on each wheel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2181 TWO-PIECE LUG NUT REPLACEMENT AFFECTED VEHICLES: 1997-1998 EXPEDITION/NAVIGATOR AND F-150/250 SERVICE PROCEDURE The following service procedure must be performed on all four (4) wheels. 1. Remove center caps from wheels. 2. Loosen lug nuts on all four (4) wheels. 3. Raise vehicle on hoist. 4. Remove all lug nuts. 5. Remove tire and wheel assemblies. 6. With wire brush, clean back of wheel (brake rotor/drum mating surface) of any foreign material. 7. Inspect all wheel stud holes for damage (cracked or distorted).If cracked or distorted (if a penny can fit through the stud hole), the wheel must be replaced. 8. Inspect all studs. Replace if damaged. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2182 9. Remove and discard hub 0-ring and any remaining pieces from the front and rear hubs. 10. Install wheel and tire assemblies. NOTE: Do not tighten lug nuts to final torque at this time. 11. Install new lug nuts and tighten enough to securely mate wheel against rotor/drum. 12. Lower vehicle and tighten lug nuts in sequence shown to 136 Nm (100 lb-ft). See Figure 4. 13. Install center caps. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2183 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2184 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2185 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2186 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2187 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2188 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2189 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 2190 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > NHTSA98V095000 > May > 98 > Recall 98V095000: Lug Nut Replacement Wheel Fastener: All Technical Service Bulletins Recall 98V095000: Lug Nut Replacement Year: 1997, 1998 Make: LINCOLN TRUCK, FORD TRUCK Model: NAVIGATOR, EXPEDITION, F150, F250 Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 1520000 Summary: Vehicle Description: Multi-purpose vehicles and light duty pickup trucks. The lug nuts on these vehicles may not create sufficient clamp load allowing wheel movement in relation to the hub/rotor mounting surface. This can result in the loosening of lug nuts, stud fatigue failure, and the potential for a wheel separation from the vehicle, increasing the risk of a vehicle crash. Dealers will inspect the wheel studs and replace the wheel lug nuts. Owner notification is expected to begin July 20, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > NHTSA98V095000 > May > 98 > Recall 98V095000: Lug Nut Defect Wheel Fastener: All Technical Service Bulletins Recall 98V095000: Lug Nut Defect NHTSA CAMPAIGN ID Number: 98V095000 Component: WHEELS: LUGS: NUTS: BOLTS Manufacturer: FORD MOTOR COMPANY Year: 1998 Make: FORD TRUCK Model: EXPEDITION Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 1520000 Summary: Vehicle Description: Multi-purpose vehicles and light duty pickup trucks. The lug nuts on these vehicles may not create sufficient clamp load allowing wheel movement in relation to the hub/rotor mounting surface. This can result in the loosening of lug nuts, stud fatigue failure, and the potential for a wheel separation from the vehicle, increasing the risk of a vehicle crash. Owners of these vehicles will be receiving two notifications. The first notification, which began in May 1998, will provide an interim repair procedure until parts become available. This interim procedure can be completed by owners or their dealers. It specifies that the lug nut torque must be verified to be 100 lbs. Then the lug nuts need to be tightened an additional 1/8 to 1/4 turn more. There will be a second owner notification, which is expected to begin July 20, 1998, under which dealers will inspect the wheel studs and replace the wheel lug nuts. Owners will be receiving two notifications. The first notification, which began in May 1998, will provide an interim repair procedure. There will be a second owner notification, which is expected to begin July 20, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Fastener Wheel Fastener: Specifications Wheel Fastener TORQUE SPECIFICATIONS Wheel Lug Nuts: 113-153 Nm (83-112 ft. lbs.) GENERAL SPECIFICATIONS Wheel Stud And Lug Nuts (Metric): M12 x 1.75 - 19 mm Hex Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Fastener > Page 2201 Wheel Fastener: Specifications Wheel Stud GENERAL SPECIFICATIONS Wheel Stud And Lug Nuts (Metric) ........................................................................................................................................... M12 x 1.75 - 19 mm Hex Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 2202 Wheel Fastener: Service and Repair REMOVAL 1. Remove the wheel hub. 2. Remove the damaged lug bolts. CAUTION: Do not press on bearing when removing or installing lug bolts. INSTALLATION 1. Install the new lug bolts. CAUTION: Do not press on bearing when removing or installing lug bolts. 2. Install the wheel hub. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation WARNING: ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. Jacking Points - Front, 4x4 The jacking point is a raised boss located on the front suspension lower arm. Jacking Points - Front, 4x2 The jacking point is a bracket welded to the frame located behind the front tire and wheel assembly. Jacking Points - Rear CAUTION: Never use the differential housing as a lifting point. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 2206 The rear jacking points are located on the rear axle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Lifting Vehicle Lifting: Service and Repair Lifting WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Lifting Points-Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Lifting Points - Drive On Hoist The vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Lifting > Page 2209 Vehicle Lifting: Service and Repair Lifting, Jacking and Hoisting WARNING: ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. Jacking Points - Front, 4x4 The jacking point is a raised boss located on the front suspension lower arm. Jacking Points - Front, 4x2 The jacking point is a bracket welded to the frame located behind the front tire and wheel assembly. Jacking Points - Rear Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Lifting > Page 2210 CAUTION: Never use the differential housing as a lifting point. The rear jacking points are located on the rear axle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Lifting > Page 2211 Vehicle Lifting: Service and Repair Vehicle Lifting and Jacking WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Lifting Points-Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Lifting Points - Drive On Hoist The vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis > Compression Test Compression Check: Testing and Inspection Compression Test 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as Compression Tester in No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, use the auxiliary starter switch to 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis > Compression Test > Page 2219 Compression Check: Testing and Inspection Interpreting Compression Readings 1. If compression improves considerably, the piston rings require service. 2. If compression does not improve, the valves are sticking or seating improperly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on the piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil and/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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis > Compression Test > Page 2220 Compression Check: Testing and Inspection Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Use the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil SAE 1OW-40XO-1OW40-QSP meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Romeo Engine Camshaft Bearing: Specifications Romeo Engine TORQUE SPECIFICATIONS Camshaft Bearing Cap Bolts: 8-12 Nm (71.4-107.1 inch lbs.) DIMENSIONS Bearing Inside Diameter (All): 27.012-26.987 mm (1.063-1.0625 inch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Romeo Engine > Page 2226 Camshaft Bearing: Specifications Windsor Engine TORQUE SPECIFICATIONS Camshaft Bearing Cap Bolts: 8-12 Nm (71.4-107.1 inch lbs.) DIMENSIONS Bearing Inside Diameter (All): 27.012-26.987 mm (1.063-1.0625 inch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Camshaft Sprocket Bolt ........................................................................................................................................................ 110-130 Nm (81-95 Ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Page 2230 Camshaft Gear/Sprocket: Testing and Inspection WARNING: TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE VEHICLE, DO NOT OPERATE THE ENGINE WITH THE HOOD OPEN UNTIL THE FAN BLADE HAS FIRST BEEN EXAMINED FOR POSSIBLE CRACKS AND SEPARATION. NOTE: ^ Specifications show the expected minimum or maximum condition. ^ If a component fails to meet the specifications, it is necessary to replace or refinish. If the component can be refinished, wear limits are provided as an aid to making a decision. Any component that fails to meet specifications and cannot be refinished must be replaced. 1. Inspect the chain and the sprockets. ^ Replace as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications DIMENSIONS End Play: Standard ...................................................................................................................................................... 0.027-0.190 mm (0.00176-0.00748 inch) Service Limit ....................................................................... .................................................................................................. 0.190 mm (0.0075 inch) Journal: Diameter (All) ................................................................................................................................................. 26.962-26.936 mm (1.061-1.060 inch) Bearing Clearance: Standard............................................................................................................................................... ...... 0.025-0.076 mm (0.00098-0.003 inch) Service Limit .................................................................... ............................................................................................. 0.076 mm (0.00239 inch) Runout ................................................................................................................................................. .................................. 0.09 mm (0.00354 inch) Lobe Lift: Allowable Lift Loss ............................................................................................................................... ................................................ 0 mm (0 inch) Intake ........................................................................... .................................................................................................... 6.58077 mm (0.25978 inch) Exhaust: Left ....................................................................................................................................................... ..................... 6.59579 mm (0.25954 inch) Right ................................................................................. ......................................................................................... 6.58551 mm (0.25327 inch) Theoretical Valve Lift @ Zero Lash: Intake ................................................................................................................................................... ...................................... 12.0 mm (0.472 inch) Exhaust ...................................................................... ................................................................................................................ 12.0 mm (0.472 inch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Journal Camshaft: Testing and Inspection Journal Clearance NOTE: The camshaft journals must meet specification before checking camshaft journal clearance. 1. Remove the camshaft bearing cap. 2. Lay Plastigage across the face of the camshaft bearing surface. 3. Position the camshaft bearing cap and install the bolts in the sequence indicated. 4. Use Plastigage to measure the camshaft journal clearance. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Journal > Page 2236 ^ If it is out of specification, replace as necessary. Diameter 1. Measure each camshaft journal diameter in two directions. ^ If it is out of specification, replace as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Journal > Page 2237 Camshaft: Testing and Inspection Lobe Lobe Lift Check the lift of each camshaft lobe in consecutive order and make a note of the readings. 1. Remove the valve covers. 2. Remove the spark plugs. 3. Install Dial Indicator with Bracketry so that the rounded tip of the indicator is on top of the camshaft lobe and on the same plane as the Hydraulic Lash Adjuster (HLA). 4. Rotate the crankshaft until the base circle of the camshaft lobe is reached. 5. Zero the Dial Indicator with Bracketry. Continue to rotate the crankshaft until the (A) high-lift point of the camshaft lobe is in the fully-raised position (highest indicator reading). 6. To check the accuracy of the original indicator reading, continue to rotate the crankshaft until (B) base circle is reached. The indicator reading should be zero. If a zero reading is not obtained' repeat Steps 1 through 6. 7. If total lift recorded on Dial Indicator with Bracketry is not within specifications; replace the camshaft. NOTE: If the lift on any lobe is below the specified service limits, the camshaft roller followers operating on that camshaft must be replaced. 8. Remove Dial Indicator with Bracketry. 9. Install the spark plugs. 10. Install the valve covers. Lobe Surface Inspect camshaft lobes for pitting or damage in the active area. Minor pitting is acceptable outside the active area. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Journal > Page 2238 Camshaft: Testing and Inspection End Play 1. Remove the roller followers. 2. Use Dial Indicator with Bracketry to measure camshaft end play. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Journal > Page 2239 Camshaft: Testing and Inspection Runout NOTE: Camshaft journals must be within specification before checking runout. 1. Use Dial Indicator with Bracketry to measure the camshaft runout. ^ Rotate the camshaft and subtract the lowest dial indicator reading from the highest dial indicator reading. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Page 2240 Camshaft: Service and Repair REMOVAL 1. Remove the valve cover. 2. Remove the timing chain/belt. CAUTION: At no time, when the timing chain/belt are removed and the cylinder heads are installed may the crankshaft or camshaft be rotated. Severe piston and valve damage will occur. 3. Remove the camshaft roller followers. 4. On engines with bolt on sprockets, remove the camshaft sprocket 1 Remove the bolt. 2 Remove the camshaft sprocket. NOTE: ^ The Windsor engine is shown; the Romeo engine is similar. Remove the thirteen camshaft bearing cap bolts. ^ The Windsor cylinder head is shown; the Romeo cylinder head is similar. Remove the camshaft bearing caps. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Page 2241 ^ Remove the camshaft from the cylinder head. INSTALLATION 1. Lubricate the camshaft journals. ^ Use engine oil meeting Ford specification WSS-M2C153-G. 2. Install the camshaft onto the cylinder head. 3. Lubricate the camshaft bearing caps. ^ Use engine oil meeting Ford specifications WSS-M2C153-G. Windsor Engine Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Page 2242 4. On Windsor engines, install the camshaft bearing caps. ^ 1 Position the camshaft bearing caps. ^ 2 Loosely install the bolts. Romeo Engine 5. On Romeo engines, install the camshaft bearing caps and loosely install the bolts. Windsor Engine Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Page 2243 6. On Windsor engines, tighten the bolts in the sequence shown. Romeo Engine 7. On Romeo engines, tighten the bolts in the sequence shown. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Page 2244 8. On Romeo engines, install the camshaft sprocket spacer. 1 Position the camshaft sprocket spacer. 2 Install the bolt. 9. Install the roller follower. 10. Install the timing chain/belt. 11. Install the valve cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Page 2245 Camshaft: Tools and Equipment Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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: > 97-25-8 > Dec > 97 > Engine - Rough Running/MIL ON/DTC'S Set Lifter / Lash Adjuster: Customer Interest Engine - Rough Running/MIL ON/DTC'S Set Article No. 97-25-8 12/08/97 ^ RUNS ROUGH - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC) P0300 THROUGH P0308 MAY BE STORED IN MEMORY - VEHICLES BUILT THROUGH 11/26/97 EQUIPPED WITH 4.6L OR 5.4L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC) P0300 THROUGH P0308 MAY BE STORED IN MEMORY - VEHICLES BUILT THROUGH 11/26/97 EQUIPPED WITH 4.6L OR 5.4L ENGINE ^ ENGINE - ROLLER FINGER FOLLOWERS DISLODGE - DURING AMBIENT TEMPERATURES LESS THAN -18 DEGREES C (0 DEGREES F) - VEHICLES BUILT THROUGH 11/26/97 EQUIPPED WITH 4.6L OR 5.4L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE: The roller finger followers may become dislodged and end up loose in the cylinder head during ambient temperatures of less than -18°C (0°F). This may result in damage to the camshaft, roller finger follower, valve, retainer, valve guide, etc. ACTION: Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Check compression of all cylinders. 2. Remove cam cover from the affected side of the engine which showed low compression readings. Look for a follower that has become dislodged and examine all components for damage (i.e., camshaft, valve, follower, etc.). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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: > 97-25-8 > Dec > 97 > Engine - Rough Running/MIL ON/DTC'S Set > Page 2254 ^ If damage is found, contact the engine plant Hotline at the numbers listed in this article. ^ If no damage is found, remove all followers from the engine (both sides) and compare to Figure 1 to determine their revision level. 3. If they are the new revision, contact the engine plant Hotline at the numbers listed in this article. It they are the old revision level, replace all followers with new level Followers (F8AZ-6564-AA). 4. Recheck compression of all cylinders to verify proper valve train operation. 5. If compression is within specifications, reinstall the cam covers and any other engine components removed. 6. If the compression is still unacceptable, contact the engine plant Hotline at the numbers listed in this article. Engine plant telephone numbers: ^ Windsor Engine - (800) 465-4680 ^ Romeo Engine - (800) 833-4503 PART NUMBER PART NAME F8AZ-6564-AA Roller Tip Follower OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972508A Compression Test - All 1.0 Hr. Models 972508B Replace Followers - 3.8 Hrs. F-Series, Expedition (4.6L MFI, 5.4L MFI) 972508C Replace Followers - 3.8 Hrs. Navigator (5.4L MFI) 972508D Replace Followers - 5.6 Hrs. Econoline (4.6L MFI) 972508E Replace Followers - 5.4 Hrs. Econoline (5.4L MFI) DEALER CODING CONDITION BASIC PART NO. CODE 6529 33 OASIS CODES: 499000, 608000, 609000, 610000, 614000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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: > 97-25-8 > Dec > 97 > Engine - Rough Running/MIL ON/DTC'S Set Lifter / Lash Adjuster: All Technical Service Bulletins Engine - Rough Running/MIL ON/DTC'S Set Article No. 97-25-8 12/08/97 ^ RUNS ROUGH - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC) P0300 THROUGH P0308 MAY BE STORED IN MEMORY - VEHICLES BUILT THROUGH 11/26/97 EQUIPPED WITH 4.6L OR 5.4L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC) P0300 THROUGH P0308 MAY BE STORED IN MEMORY - VEHICLES BUILT THROUGH 11/26/97 EQUIPPED WITH 4.6L OR 5.4L ENGINE ^ ENGINE - ROLLER FINGER FOLLOWERS DISLODGE - DURING AMBIENT TEMPERATURES LESS THAN -18 DEGREES C (0 DEGREES F) - VEHICLES BUILT THROUGH 11/26/97 EQUIPPED WITH 4.6L OR 5.4L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE: The roller finger followers may become dislodged and end up loose in the cylinder head during ambient temperatures of less than -18°C (0°F). This may result in damage to the camshaft, roller finger follower, valve, retainer, valve guide, etc. ACTION: Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Check compression of all cylinders. 2. Remove cam cover from the affected side of the engine which showed low compression readings. Look for a follower that has become dislodged and examine all components for damage (i.e., camshaft, valve, follower, etc.). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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: > 97-25-8 > Dec > 97 > Engine - Rough Running/MIL ON/DTC'S Set > Page 2260 ^ If damage is found, contact the engine plant Hotline at the numbers listed in this article. ^ If no damage is found, remove all followers from the engine (both sides) and compare to Figure 1 to determine their revision level. 3. If they are the new revision, contact the engine plant Hotline at the numbers listed in this article. It they are the old revision level, replace all followers with new level Followers (F8AZ-6564-AA). 4. Recheck compression of all cylinders to verify proper valve train operation. 5. If compression is within specifications, reinstall the cam covers and any other engine components removed. 6. If the compression is still unacceptable, contact the engine plant Hotline at the numbers listed in this article. Engine plant telephone numbers: ^ Windsor Engine - (800) 465-4680 ^ Romeo Engine - (800) 833-4503 PART NUMBER PART NAME F8AZ-6564-AA Roller Tip Follower OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972508A Compression Test - All 1.0 Hr. Models 972508B Replace Followers - 3.8 Hrs. F-Series, Expedition (4.6L MFI, 5.4L MFI) 972508C Replace Followers - 3.8 Hrs. Navigator (5.4L MFI) 972508D Replace Followers - 5.6 Hrs. Econoline (4.6L MFI) 972508E Replace Followers - 5.4 Hrs. Econoline (5.4L MFI) DEALER CODING CONDITION BASIC PART NO. CODE 6529 33 OASIS CODES: 499000, 608000, 609000, 610000, 614000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Page 2261 Lifter / Lash Adjuster: Specifications DIMENSIONS Diameter (Std) ......................................................................................................................................................... 16.000-15.988 mm (0.63-0.629 inch) Clearance To Bore ............................................................................................................................................ 0.018-0.069 mm (0.00071-0.00272 inch) Service Limit ....................................................................... ...................................................................................................... 0.016 mm (0.00063 inch) Collapsed Lash Adjuster Gap Desired ...................................................................................................................... 0.85-0.45 mm (0.0335-0.0177 inch) LEAKDOWN Hydraulic Leakdown Rate [1] ............................................................................................................... ........................................................ 5-25 seconds [1] Time required for plunger to leak down 1.6 mm of travel with 222 N force and leak down fluid in tappet Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Page 2262 Lifter / Lash Adjuster: Testing and Inspection Inspect the roller for flat spots or scoring. If any damage is found, inspect the camshaft lobes and hydraulic lash adjusters for damage. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Page 2263 Lifter / Lash Adjuster: Service and Repair REMOVAL 1. Remove the valve cover. 2. Position the piston of the cylinder being repaired at the bottom of the stroke. 3. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage. 4. Use the Valve Spring Compressor to compress the valve springs and remove the cam roller followers. INSTALLATION 1. Use the (A) Valve Spring Compressor to compress the (B) valve spring and install the (C) camshaft roller followers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Page 2264 2. Remove the Valve Spring Spacer. 3. Install the valve cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Page 2265 Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2274 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2275 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2281 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2282 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2283 Rocker Arm Assembly: Specifications DIMENSIONS Rocker Arm-Ratio ................................................................................................................................ .................................................................... 1.75:1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications DIMENSIONS Bearing Wall Thickness (STD): 1.918-1.926 mm Clearance to Crankshaft: Desired: 0.026-0.064 mm Allowable: 0.26-0.064 mm TORQUE SPECIFICATIONS Tighten the connecting rod bolts in two stages, using the sequence shown. ^ Stage 1: 40-45 Nm (29-33 ft. lbs.). ^ Stage 2: Rotate 90-120 degrees. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt Connecting Rod: Specifications Romeo Engines Romeo Engines Connecting Rod Cap Bolts Step 1 40-45 Nm (30-33 ft.lb) Step 2 Rotate 90°-120° Windsor Engines Connecting Rod Bolts Step 1 40-45 Nm (30-33 ft.lb) Step 2 Rotate 90°-120° Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt > Page 2292 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt > Page 2293 Connecting Rod: Specifications Connecting Rod, Engine DIMENSIONS Alignment (Bore-to-Bore Max. Diff.): Twist [1] ............................................................................................................................................... .................................... + 1.27 mm (0.05 inch) Bend ........................................................................... ........................................................................................................ + 0.038 mm (0.0014 inch) Bore Diameter: Crankshaft Bearing: Windsor ............................................................................................................................................... .................................... 56.866-56.886 mm Romeo ............................................................................. ......................................................................................................... 56.756-58.876 mm Piston Pin..................................................................................................................................................... 22.012-22.024 mm (0.8665-0.8677 inch) Length: Center-to-Center .................................................................................................................................. ...................................... 150.7 mm (5.93 inch) Side Clearance (Assembled to Crank): Standard ............................................................................................................................................................ 0.015-0.45 mm (0.0006-0.0177 inch) Service Limit ............................................................................. .................................................................................................. 0.50 mm (0.02 inch) [1] Pin bore and crank bearing bore must be parallel and in same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 101.5 mm on each side of rod centerline.-Twist mm (inch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance Connecting Rod: Testing and Inspection Connecting Rod Bearing Journal Clearance 1. Remove the connecting rod bearing cap. NOTE: The crankshaft connecting rod journals must be within specification to check the connecting rod bearing journal clearance. 2. Position a piece of Plastigage across the bearing surface. 3. Install and tighten to specifications, then remove the connecting rod bearing cap. NOTE: Do not turn the crankshaft during this step. 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 bearing or connecting rod. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance > Page 2296 Connecting Rod: Testing and Inspection Connecting Rod Bend Measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance > Page 2297 Connecting Rod: Testing and Inspection Connecting Rod Bushing Diameter Measure the inner diameter of the connecting rod bushing. Verify the diameter is within specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance > Page 2298 Connecting Rod: Testing and Inspection Connecting Rod Large End Bore Measure the bore in two directions. The difference is the connecting rod bore out-of-round. Verify the out-of-round is within specification. 1 Romeo engine. 2 Windsor engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance > Page 2299 Connecting Rod: Testing and Inspection Connecting Rod Bearing Journal Clearance 1. Remove the connecting rod bearing cap. NOTE: The crankshaft connecting rod journals must be within specification to check the connecting rod bearing journal clearance. 2. Position a piece of Plastigage across the bearing surface. 3. Install and tighten to specifications, then remove the connecting rod bearing cap. NOTE: Do not turn the crankshaft during this step. 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 bearing or connecting rod. Connecting Rod Bend Measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification. Connecting Rod Bushing Diameter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance > Page 2300 Measure the inner diameter of the connecting rod bushing. Verify the diameter is within specification. Connecting Rod Large End Bore Measure the bore in two directions. The difference is the connecting rod bore out-of-round. Verify the out-of-round is within specification. 1 Romeo engine. 2 Windsor engine. Connecting Rod Piston Pin Side Clearance Measure the clearance between the connecting rod and the piston. Verify the measurement is within specification. Connecting Rod Twist Measure the connecting rod twist on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the measurement is within specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Page 2301 Connecting Rod: Service and Repair CAUTION: Do not use a caustic cleaning solution or damage to connecting rods may occur. NOTE: The connecting rod large end is mechanically split to produce a unique parting face. This produces a locking joint. Parts are not interchangeable. Mark and separate the parts and clean with solvent. Clean the oil passages. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Page 2302 Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications TORQUE SPECIFICATIONS Cylinder Block Drain Plug ......................................................................................................................................................... 16-24 Nm (11-18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Main Bearing Clearance to Crankshaft ......................................................................................................................... 0.027-0.065 mm (0.0011-0.0026 in) Bearing Wall Thickness .................................................................................................................................................... 1.920-1.928 mm (0.075-0.076 in) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > General Specifications > Page 2310 Crankshaft Main Bearing: Specifications Torque Specifications and Procedures Romeo Engines Torque Specifications - Crankshaft Main Bearing Bolts Install the vertical main bearing cap fasteners and tighten the bolts in two stages, in the sequence shown. - Stage 1: Tighten to 40 Nm (30 ft. lbs.). - Stage 2: Tighten an additional 90 degrees. Tighten the jack screws against the cylinder block in two stages, in the sequence shown. - Stage 1: Tighten to 5 Nm (44 in. lbs.) - Stage 2: Tighten to 10 Nm (89 in. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > General Specifications > Page 2311 Install the side bolts and tighten them in the sequence shown. Windsor Engines Torque Specifications - Crankshaft Main Bearing Bolts Vertical Tighten the bolts in two steps in the sequence shown. Step 1: Tighten to 40 Nm (30 ft. lbs.). - Step 2: Tighten an additional 90 degrees. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > General Specifications > Page 2312 Side Bolts Install the side bolts and tighten in two steps, in the sequence shown. Step 1: Tighten to 27-33 Nm (20-24 ft. lbs.). - Step 2: Tighten an additional 85-95 degrees. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2313 Crankshaft Main Bearing: Testing and Inspection Inspect the bearings for the following defects. Possible causes are shown: ^ Cratering-fatigue failure (A). ^ Spot polishing-improper seating (B). ^ Scratching-dirty (C). ^ Base exposed-poor lubrication (D). ^ Both edges worn-journal damaged (E). ^ One edge worn-journal tapered or bearing not seated (F). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Romeo Engines Crankshaft: Specifications Romeo Engines DIMENSIONS Free End Play .......................................................................................................................................................... 0.130-0.301 mm (0.0051-0.012 inch) Journal Diameter: Connecting Rod ............................................................................................................................................... 52.988-53.003 mm (2.087-2.867 inch) Main Bearing ..................................................................................................................................................... 67.481-67.505 mm (2.65-2.657 inch) Journal Taper: Connecting Rod ................................................................................................................................... .................................. 0.015 mm (0.0005 inch) Main Bearing ............................................................. ............................................................................................................ 0.020 mm (0.0007 inch) Main Bearing Journal Runout .......................................................................................................................................................... 0.05 mm (0.002 inch) Runout To Rear Block Face .................................................................................................................................................. 0.050 mm (0.002 inch, max) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Romeo Engines > Page 2318 Crankshaft: Specifications Windsor Engines DIMENSIONS Free End Play ....................................................................................................................................................... 0.075-0.377 mm (0.0023-0.0143 inch) Journal Diameter: Connecting Rod ............................................................................................................................................... 52.988-53.003 mm (2.087-2.867 inch) Main Bearing ..................................................................................................................................................... 67.481-67.505 mm (2.65-2.657 inch) Journal Taper: Connecting Rod ................................................................................................................................... .................................. 0.015 mm (0.0005 inch) Main Bearing ............................................................. ............................................................................................................ 0.008 mm (0.0030 inch) Main Bearing Journal Runout .......................................................................................................................................................... 0.05 mm (0.002 inch) Runout To Rear Block Face .................................................................................................................................................. 0.050 mm (0.002 inch, max) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > End Play Crankshaft: Testing and Inspection End Play 1. Use Dial Indicator with Bracketry to measure crankshaft end play. 1 Romeo engine. 2 Windsor engine. ^ If crankshaft end play exceeds specifications, replace the crankshaft thrust washers or thrust bearing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > End Play > Page 2321 Crankshaft: Testing and Inspection Journal Connecting Rod Journal Diameter Measure the crankshaft connecting rod journal diameters in at least two directions perpendicular of one another. The difference between the measurements is the out-of-round. Verify the journal is within the wear limit specification. Undersize connecting rod bearings will need to be installed. Connecting Rod Journal Taper Measure the crankshaft connecting rod journal diameters in two directions perpendicular of 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. Undersize connecting rod bearings will need to be installed. Main Bearing Journal Clearance NOTE: Crankshaft main bearing journals must be within specification before checking journal clearance. 1. Remove the crankshaft main bearing caps and bearings. 2. Lay a piece of Plastigage across the face of each crankshaft main bearing surface. 3. Install and remove the crankshaft main bearing cap. NOTE: Do not turn the crankshaft while doing this procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > End Play > Page 2322 4. Verify the crankshaft journal clearance. ^ If it is out of specification, replace as necessary. Main Bearing Journal Diameter Measure each of the crankshaft main bearing journal diameters in at least two directions. ^ If it is out of specification, replace as necessary. Main Bearing Journal Taper Measure each of the crankshaft main bearing journal diameters in at least two directions at each end of the main bearing journal. ^ If it is out of specification, replace as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > End Play > Page 2323 Crankshaft: Testing and Inspection Runout NOTE: Crankshaft main bearing journals must be within specifications before checking runout. 1. Use Dial Indicator with Bracketry 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, replace as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > Page 2324 Crankshaft: Tools and Equipment Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications Engine Block Heater: Specifications TORQUE SPECIFICATIONS Block Heater Screw .............................................................................................................................................................. 1.6-1.8 Nm (14-16 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 2328 Engine Block Heater: Service and Repair REMOVAL 1. Drain the engine cooling system. 2. Disconnect the (A) block heater wire extension from the (B) block heater wiring and remove. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Disconnect the (A) block heater wiring from the (B) block heater. 5. Remove the block heater. 1 Loosen the screw. 2 Twist and slide the block heater to release the retainer clip and remove. Discard the retainer clip. CAUTION: Do not loosen the screw more than necessary for removal. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 2329 1. Lower the vehicle. Follow the removal procedure in reverse order. NOTE: ^ To ease installation, coat the block heater seal and the cylinder block hole with Premium Long Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. ^ If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 REMOVAL 1. Use Slide Hammer to remove the cylinder block core plug. 2. Inspect the cylinder block plug bore for any damage that would interfere with the proper sealing of the plug. If the cylinder block plug bore is damaged, bore for the next oversize plug. NOTE: Oversize plugs are identified by the "OS" stamped in the flat located on the cup side of the plug. 3. Coat the cylinder block core plug and bore lightly with Thread Lock 262 E2FZ-19554-B or equivalent meeting Ford specification WSK-M2G351-A6 and install the cylinder block core plug. INSTALLATION Cup Type Use a fabricated tool to seat the cup type cylinder block core plug. CAUTION: ^ Do not contact the flange when installing a cup type cylinder block core plug. This could damage the sealing edge and result in leakage. ^ When installed, the flanged edge must be below the chamfered edge of the bore to effectively seal the bore. Expansion Type 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 a fabricated tool to seat the expansion type cylinder block core plug. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair > Page 2333 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Front Engine Plate > Component Information > Specifications Front Engine Plate: Specifications TORQUE SPECIFICATIONS Tighten the engine front cover fasteners in two stages in the sequence shown. ^ Stage 1: Tighten fasteners 1-5 to 20-30 Nm (15-22 ft. lbs.). ^ Stage 2: Tighten fasteners 6-15 to 40-55 Nm (30-41 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Front Engine Plate > Component Information > Specifications > Page 2337 Front Engine Plate: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove both valve covers. 3. Remove the radiator. 4. Remove the water pump. 5. Disconnect the following electrical connections: ^ LH ignition coil connector (A). ^ Camshaft Position Sensor (CMP) electrical connector (B). ^ Radio capacitor electrical connector (C). 6. Disconnect the following electrical connections: ^ RH ignition coil electrical connector (A) ^ radio capacitor electrical connector (B) 7. Remove the ignition coils and the ignition coil mounting brackets. 1 Remove the bolts. 2 Remove the RH ignition coil and the ignition coil mounting bracket. 3 Remove the bolt. 4 Remove the nuts. 5 Remove the LH ignition coil and ignition coil mounting bracket. 8. Raise and support the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Front Engine Plate > Component Information > Specifications > Page 2338 9. Remove the bolts and position the power steering pump aside. 10. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 11. Remove the oil pan drain plug and drain the engine oil. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Front Engine Plate > Component Information > Specifications > Page 2339 12. Remove the bolts. 13. Lower the vehicle. 14. Remove the crankshaft front seal. 15. Remove the (A) bolt and the (B) belt idler pulley. 16. Remove the bolts and stud bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Front Engine Plate > Component Information > Specifications > Page 2340 17. Remove the engine front cover from the front cover to cylinder block dowel. INSTALLATION 1. Apply silicone along the cylinder head to block surface and the oil pan to cylinder block surface. ^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A. Allow to dry until there is no sign of wetness, or four minutes, which ever is longer. Failure to follow this procedure can cause future oil leakage. 2. Install the engine front cover on the front cover to cylinder block dowel and loosely install the bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Front Engine Plate > Component Information > Specifications > Page 2341 3. Tighten the front cover bolts and stud bolts in sequence in two steps. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Front Engine Plate > Component Information > Specifications > Page 2342 Step 1: Tighten fasteners 1-7 to 20-30 Nm (15-22 ft. lbs.). Step 2: Tighten fasteners 6-15 to 40-55 Nm (29-40 ft. lbs.). 4. Position the (A) belt idler pulley and install the (B) bolt. 5. Install a new engine front cover front oil seal. 6. Raise and support the vehicle. 7. Loosely install the four front oil pan bolts. 8. Tighten the bolts in the sequence shown in two steps. 1 Tighten to 20 Nm (15 ft. lbs.). 2 Tighten an additional 60 degrees. NOTE: Make sure to tighten the bolts in two steps. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Front Engine Plate > Component Information > Specifications > Page 2343 9. Connect the CKP sensor electrical connector. 10. Position the power steering pump and install the bolts. NOTE: The front lower hole in the power steering pump is not used. 11. Install the oil pan drain plug. 12. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Front Engine Plate > Component Information > Specifications > Page 2344 13. Install the ignition coils and brackets. 1 Position the LH ignition coil and the ignition coil mounting bracket. 2 Install the LH nuts. 3 Install the LH bolt. 4 Position the RH ignition coil and ignition coil mounting bracket. 5 Install the RH bolts. 14. Connect the following electrical connections: ^ RH ignition coil electrical connector (A) ^ radio capacitor electrical connector (B) 15. Connect the following electrical connections: ^ LH ignition coil connector (A) ^ CMP electrical connector (B) ^ radio capacitor electrical connector (C) 16. Install the valve covers. 17. Install the water pump. 18. Install the radiator. 19. Connect the battery ground cable. 20. Fill the engine with oil. ^ Use engine oil meeting Ford specification WSS-M2C153-G. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Tighten the crankshaft pulley bolt in four stages. ^ Stage 1: 90 Nm (66 ft. lbs.). ^ Stage 2: Loosen 360 degrees. ^ Stage 3: 47-53 Nm (35-39 ft. lbs.). ^ Stage 4: Rotate 85-90 degrees. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2348 Harmonic Balancer - Crankshaft Pulley: Service and Repair REMOVAL 1. Remove the engine cooling fan and fan shroud. 2. Remove the drive belt. 3. Remove the crankshaft pulley bolt. 4. Use the Crankshaft Damper Remover to remove the crankshaft pulley. INSTALLATION 1. Apply silicone to the woodruff key slot on the crankshaft pulley. ^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. NOTE: The crankshaft pulley must be installed within four minutes after applying the silicone. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2349 2. Use the Crankshaft Damper Replacer to install the crankshaft pulley. 3. Install the bolt and washer. Tighten the bolt in four steps. ^ Step 1: Tighten to 90 Nm (66.15 ft.lbs.). ^ Step 2: Loosen the bolt. ^ Step 3: Tighten to 47-53 Nm (34-39 ft. lbs.). ^ Step 4: Tighten an additional 85-90 degrees. 4. Install the drive belt. 5. Install the engine cooling fan and the fan shroud. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2350 Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications DIMENSIONS Pin Bore Diameter ............................................................................................................................................... 22.004-22.008 mm (0.866-0.8663 inch) Piston-to-Bore [1]: Clearance .............................................................................................................................................. -0.005 to +0.025 mm (-0.00019 to +0.00038) Ring Groove Width: Compression (Top) ........................................................................................................................................... 1.530-1.550 mm (0.060-0.0610 inch) Compression (Bottom) .................................................................................................................................... 1.520-1.540 mm (0.0593-0.0605 inch) Oil Ring ....................................................................................................... ........................................................ 3.03-3.05 mm (0.1192-0.1207 inch) [1] @ 43 mm from top. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Cleaning and Inspection Piston: Testing and Inspection Cleaning and Inspection CAUTION: Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage may occur. 1. Clean and inspect the (A) ring lands, the (B) skirts. the (C) pin bosses, and the (D) top of the pistons. If wear marks or polishing is found on the piston skirt, check for a bent or twisted connecting rod. 2. Use Piston Ring Groove Cleaner to clean the piston ring grooves. ^ Make sure the oil ring holes are clean. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Cleaning and Inspection > Page 2356 Piston: Testing and Inspection Diameter Measure the piston skirt diameter. Pistons come in three color codes: ^ coded red (A) ^ coded blue (B) ^ coded yellow (C) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Cleaning and Inspection > Page 2357 Piston: Testing and Inspection Pin Bore Diameter 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. EYE PROTECTION SHOULD BE WORN. NOTE: Pistons 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Cleaning and Inspection > Page 2358 Piston: Testing and Inspection Piston Selection NOTE: The cylinder bore must be within specification for taper and out-of-round before fitting a piston. 1. Select a piston size based on the cylinder bore. 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. 2. Choose the piston with the proper paint color. ^ Red-in the lower third of the size range. ^ Blue-in the middle third of the size range. ^ Yellow-in the upper third of the size range. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Cleaning and Inspection > Page 2359 Piston: Testing and Inspection Piston to Cylinder Bore Clearance Subtract the piston diameter from the cylinder bore diameter to find the piston to cylinder bore clearance. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Page 2360 Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications DIMENSIONS Diameter .................................................................................................................................................... 22.0005-22.0030 mm (0.86616-0.86625 inch) Length ........................................................................ ........................................................................................... 61.601-62.030 mm (2.425-2.442 inch) Pin to Piston Clearance ................................................................................................................................... 0.0009-0.005 mm (0.00073-0.00019 inch) Pin to Rod Clearance ....................................................................................................................................... 0.0093-0.023 mm (0.00036-0.00030 inch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 2364 Piston Pin: Testing and Inspection Measure the piston pin diameter in two directions at points shown. Verify the diameter is within specification. 1 Romeo engine. 2 Windsor engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Service and Repair > Floating Pin Piston Pin: Service and Repair Floating Pin DISASSEMBLY 1. Remove the clips. 2. Remove the piston pin from the piston and connecting rod assembly. 3. Remove the connecting rod from the piston. 4. Clean and inspect the piston and connecting rod. ASSEMBLY NOTE: Connecting rod must be installed into piston with identification markings toward front. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Service and Repair > Floating Pin > Page 2367 1. Position the connecting rod in the piston. 2. Lubricate the piston pin and pin bore. ^ Use engine oil meeting Ford specification WSS-M2C1 53-G. 3. Install the piston pin in the piston and connecting rod assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Service and Repair > Floating Pin > Page 2368 4. Install the piston pin retaining clips in the piston. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Service and Repair > Floating Pin > Page 2369 Piston Pin: Service and Repair Press Fit DISASSEMBLY 1. Use the Piston Pin Tool to press the piston pin out from the connecting rod and piston assembly. 2. Remove the connecting rod from the piston. 3. Clean and inspect the connecting rod and piston. ASSEMBLY 1. Lubricate the piston pin and piston pin bore. ^ Use engine oil meeting Ford specification WSS-M2C153-G. NOTE: The connecting rod can be installed in either direction. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Service and Repair > Floating Pin > Page 2370 2. Position the piston pin in the bore aligned with the connecting rod bore. 3. Use the Piston Pin Tool to press the piston pin into the piston and rod assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Service and Repair > Page 2371 Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications DIMENSIONS Oil Ring: Side Clearance ................................................................................................................................................. 0.027-0.196 mm (0.0017-0.0077 inch) Compression (Top) ............................................................................................................................................. 0.03-0.08 mm (0.0012-0.0031 inch) Compression (Bottom) .................................................................................................................................... 0.030-0.080 mm (0.0012-0.0031 inch) Ring Gap: Compression (Top) ............................................................................................................................................. 0.13-0.28 mm (0.0051-0.0117 inch) Compression (Bottom) ........................................................................................................................................ 0.25-0.40 mm (0.0093-0.0157 inch) Oil Ring (Steel Rail) ............................................................................................................................................ 0.13-0.28 mm (0.0051-0.0117 inch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Testing and Inspection > End Gap Piston Ring: Testing and Inspection End Gap CAUTION: ^ Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore. ^ Piston rings should not be transferred from one piston to another. NOTE: Cylinder bore must be within specification for taper and out-of-round to fit piston rings. 1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel. 2. Measure the top piston ring end gap. 3. Measure the 2nd piston ring end gap. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Testing and Inspection > End Gap > Page 2377 Piston Ring: Testing and Inspection Ring to Groove Clearance 1. Inspect for a step in the grooves. 2. Measure the piston ring-to-groove clearance. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Testing and Inspection > Page 2378 Piston Ring: Tools and Equipment Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer does not indicate whether this vehicle has adjustable or non-adjustable valves. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 EFI/CFI Fuel Pressure Gauge WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place the fuel in a suitable container. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2394 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2395 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2401 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2402 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2403 Rocker Arm Assembly: Specifications DIMENSIONS Rocker Arm-Ratio ................................................................................................................................ .................................................................... 1.75:1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Romeo Valve Cover: Specifications Romeo TORQUE SPECIFICATIONS Tighten the LH cam cover bolts in the sequence shown 8-12 Nm (71-106 inch lbs.) Tighten the RH cam cover bolts in the sequence shown: 8-12 Nm (71-106 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Romeo > Page 2408 Valve Cover: Specifications Windsor TORQUE SPECIFICATIONS Tighten the LH cam cover bolts in the sequence shown 8-12 Nm (71-106 inch lbs.) Tighten the RH cam cover bolts in the sequence shown: 8-12 Nm (71-106 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side Valve Cover: Service and Repair Right Side REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the crankcase ventilation hose from the valve cover. 3. Loosen the valve cover bolts and remove the valve cover. ^ Remove the valve cover gasket. Clean and inspect the mating surface. INSTALLATION CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. 1. Apply the silicone in two places where the engine front cover meets the cylinder head. ^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. 2. Position the valve cover on the cylinder head and loosely install the valve cover bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2411 Romeo Engine Windsor Engine 3. Tighten the bolts in the sequence shown. 4. Install the Positive Crankcase Ventilation valve (PCV valve) and crankcase ventilation hose into the valve cover. 5. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2412 Valve Cover: Service and Repair Left Side REMOVAL 1. Remove the engine air cleaner and the air cleaner outlet tube. 2. Disconnect the power steering fluid reservoir and bracket. 1 Remove the bolts. 2 Position the power steering fluid reservoir and bracket aside. 3. Remove the crankcase ventilation tube from the valve cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2413 4. Remove the EGR valve to exhaust manifold tube. ^ Disconnect the upper and lower EGR valve to exhaust manifold tube fittings. ^ Disconnect the two DPFE hoses. 5. Remove the LH valve cover. ^ Fully loosen the bolts and remove the valve cover. ^ Inspect the valve cover gasket and clean the mating surface of the cylinder head. INSTALLATION NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-A or equivalent meeting Ford specification WSE-M5B392-A. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. 1. Apply a bead of silicone in two places where the engine front cover meets the cylinder head. ^ Use Silicone Gasket and Sealer F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2414 2. Position the (A) valve cover and the valve cover gasket on the (B) cylinder head, and loosely install the bolts. ^ Romeo Engine ^ Windsor Engine Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2415 3. Tighten the bolts in the sequence shown. 4. Position the fuel charging wiring onto the valve cover studs. 5. Connect the following EGR valve-to-exhaust manifold tube connectors: ^ two DPFE transducer hoses ^ EGR valve to the exhaust manifold tube upper fitting ^ EGR exhaust tube lower fitting 6. Install the engine Air Cleaner (ACL) and air cleaner outlet tube. 7. Install the power steering fluid reservoir and bracket. 1 Position the power steering fluid reservoir and bracket. 2 Install the bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications DIMENSIONS Valve Guide Inner Diameter ................................................................................................................ .................................................... 7.015-7.044 mm Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 2419 Valve Guide: Testing and Inspection 1. Measure the inner diameter of the valve guides in two directions where indicated. 2. If the valve guide is not within specification, 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 2420 Valve Guide: Service and Repair 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications DIMENSIONS Valve Seat Angle ................................................................................................................................. ......................................................................... 45° Valve Seat Runout (T.I.R.) ............................................................................................................................................... 0.025 mm (0.00038 inch, max) Valve Seat Width: Intake ................................................................................................................................................... ........................ 1.9-2.1 mm (0.074-0.082 inch) Exhaust ..................................................................... ................................................................................................... 1.9-2.1 mm (0.074-0.082 inch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Testing and Inspection > Inspection Valve Seat: Testing and Inspection Inspection CAUTION: After grinding valves or valve seats, check the valve clearance Check the valve seat and valve angles. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Testing and Inspection > Inspection > Page 2426 Valve Seat: Testing and Inspection Runout Use a suitable valve seat Snout gauge to check valve seat runout. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Testing and Inspection > Inspection > Page 2427 Valve Seat: Testing and Inspection Width Measure the valve seat width. If necessary, grind the valve seat to specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications DIMENSIONS Valve Springs-Compression Pressure Intake [1] .............................................................................................................................................. ......................... 633.3-701.3 N (142-158 lbs.) Exhaust [1] .................................................................. ................................................................................................. 633.3-701.3 N (142-158 lbs.) Valve Springs-Free Length (Approximate) Intake ................................................................................................................................................... ........................................................... 50.2 mm Exhaust ..................................................................... ...................................................................................................................................... 50.2 mm Valve Springs-Installed Height ............................................................................................................ ...................................................... 39.7 - 40.3 mm Valve Springs-Installed Pressure Intake [2] .............................................................................................................................................. ............................. 272.1-306.1 N (61-69 lbs.) Exhaust [2] .................................................................. ...................................................................................................... 272.1-306.1 N (61-69 lbs.) Service Limit [1] ................................................................................................................................................ .............................. 3% Pressure Loss Out of Square Limit .............................................................................................................................. ........................................................... 2.5 degrees [1] @ 28.02 mm (1.103 inch) [2] @ 40.0 mm (1.574 inch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Free Length Valve Spring: Testing and Inspection Free Length Measure the free length of each valve spring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Free Length > Page 2433 Valve Spring: Testing and Inspection Installed Length Measure the installed length of each valve spring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Free Length > Page 2434 Valve Spring: Testing and Inspection Squareness 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. Replace the valve spring if out of specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Free Length > Page 2435 Valve Spring: Testing and Inspection Strength Use Valve/Clutch Spring Tester to check the valve springs for proper strength at the specified valve spring length. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Page 2436 Valve Spring: Service and Repair REMOVAL 1. Remove the camshaft roller followers. 2. Position the piston at the top of the stroke. 3. Remove the spark plug and install compressed air in the cylinder to hold both valves in position. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal. 4. Use the Valve Spring Compressor to compress the valve springs. 5. Remove the (A) valve spring retainer keys, the (B) valve spring retainers, and the (C) valve spring. INSTALLATION 1. Position the valve spring and the valve spring retainers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Page 2437 2. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage. 3. Use the Valve Spring Compressor to compress the valve spring. Install the valve spring retainer keys. 4. Install the camshaft roller followers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Page 2438 Valve Spring: Tools and Equipment Special Tool(s) Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold Valve: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold > Page 2447 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold > Page 2448 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Valve: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2454 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2455 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Page 2456 Valve: Specifications DIMENSIONS Valve Arrangement (Front-to-Rear) Left Hand ............................................................................................................................................. ................................................ E-I-E-I-E-I-E-I Right Hand ................................................................... ........................................................................................................................ I-E-I-E-I-E-I-E Valve Stem to Guide Clearance Intake ........................................................................................................................................................... 0.020-0.069 mm (0.00078-0.00272 inch) Exhaust .............................................................................................................................................................. 0.046-0.095 mm (0.018-0.0037 inch) Valve Head Diameter Intake ................................................................................................................................................... ........................................ 44.5 mm (1.75 inch) Exhaust ...................................................................... .................................................................................................................. 34.0 mm (1.34 inch) Gauge Diameters .................................................................................................................................................. 42.5 and 32.0 mm (1.67 and 1.26 inch) Valve Face Runout Limit ..................................................................................................................... ............................................ 0.05 mm (0.002 inch) Valve Face Angle ................................................ ........................................................................................................................................... 45.5 degrees Valve Stem Diameter (Std) Intake ................................................................................................................................................... .............. 6.995-6.975 mm (0.275-0.2746 inch) Exhaust .............................................................................................................................................................. 6.970-6.949 mm (0.274-0.2736 inch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection Valve: Testing and Inspection Inspection Inspect the following valve areas: 1 The end of the stem for grooves or scoring (A). 2 The valve face and the edge for pits, grooves or scores (B). 3 The valve head for signs of burning, erosion, warpage and cracking. Minor pits, grooves and other abrasions may be removed (C). 4 The valve face width (D). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection > Page 2459 Valve: Testing and Inspection Stem Diameter 1. Measure the diameter of each intake valve stem at the points shown. Verify the diameter is within specification. 2. Measure the diameter of each exhaust valve stem at the points shown. Verify the diameter is within specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection > Page 2460 Valve: Testing and Inspection Stem to Guide Clearance NOTE: Valve stem diameter must be within specification before checking valve stem to valve guide clearance. 1. Install Valve Stem Clearance Tool on the valve stem and install Dial Indicator with Bracketry. Lower the valve until Valve Stem Clearance Tool contacts the upper surface of the valve guide. 2. Move the Valve Stem Clearance Tool toward the Dial Indicator and zero the Dial Indicator with Bracketry. Move the Valve Stem Clearance Tool away from the Dial Indicator with Bracketry and note the reading. The reading will be double the valve stem-to-valve guide clearance. Valves with oversize stems will need to be installed if out of specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Page 2461 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation Drive Belt: Description and Operation The accessory drive consists of the: drive belt. ^ generator pulley. ^ power steering pump pulley. ^ crankshaft pulley. ^ A/C clutch pulley. ^ belt idler pulley. ^ drive belt tensioner. ^ water pump pulley. The accessory drive: ^ has a single serpentine drive belt. ^ has an automatic drive belt tensioner. ^ does not require adjustment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 1. Verify customer concern by running the engine. 2. Inspect the drive belt for chunking, fraying and wear. 3. Check the drive belt for correct routing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 2468 Drive Belt: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 2469 Drive Belt: Component Tests and General Diagnostics Belt Tension NOTE: Drive belt tension is not adjustable. The drive belt tensioner automatically adjusts drive belt tension. Check the automatic drive belt tensioner: 1. With the engine off, check for proper drive belt routing. 2. Rotate the drive belt tensioner and check for a binding or frozen condition. Replace components as required. Cracking/Chunking/Wear V-Ribbed Belt With Cracks (Acceptable) Vee Ribbed Serpentine Drive Belt With Cracks Across Backing V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) Vee Ribbed Belt With Chunks of Rib Missing Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. Non-standard replacement drive belts may track differently or improperly. If a replacement drive belt tracks improperly, replace it with an original equipment drive belt to avoid performance failure or loss of drive belt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 2470 With the engine running, check drive belt tracking. If the (A) edge of the drive belt rides beyond the edge of the pulleys, noise and premature wear may occur. Make sure the (B) drive belt rides correctly on the pulley. If a drive belt tracking condition exists, proceed with the following: Visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. This will result in chirp and squeal noises. ^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Replace components as required. ^ Check all accessories, mounting brackets and the drive belt tensioner for any interference that would prevent the component from mounting properly. Correct any interference condition and recheck the drive belt tracking. ^ Tighten all accessories, mounting brackets, and drive belt tensioner retaining hardware to specification. Recheck the drive belt tracking. Drive Belt Noise/Flutter NOTE: Tensioner is shown in free-state position against arm travel stops. Part 1 Of 2 Part 2 Of 2 Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged pulley or an improperly aligned pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley, look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain conditions, such as: engine start up, rapid Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 2471 engine acceleration, or A/C clutch engagement. Drive belt squeal can occur under certain conditions: ^ If the A/C discharge pressure goes above specifications: the A/C system is overcharged. - the A/C condenser core airflow is blocked. ^ If the A/C OFF equalized pressure (the common discharge and suction pressure that occurs after several minutes) exceeds specifications. ^ If any of the accessories are damaged, have a worn or damaged bearing, internal torsional resistance above normal. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. ^ If fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive belt with soap and water and thoroughly rinse with clean water. The drive belt does not have to be replaced if no apparent damage has occurred. ^ If the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the drive belt tensioner indicator is outside the installation wear range window, replace the drive belt. NOTE: The drive belt tensioner arm should rotate freely without binding. ^ If the drive belt tensioner is worn or damaged. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2472 Drive Belt: Service and Repair REMOVAL 1. Use (B) 1/2 inch square hole in drive belt tensioner pulley hub to rotate (A) drive belt tensioner clockwise and remove the (C) drive belt. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications TORQUE SPECIFICATIONS Drive Belt Tensioner Bolts .................................................................................................................................................. 21.2-28.8 Nm (16-22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 2476 Drive Belt Tensioner: Service and Repair REMOVAL 1. Remove the drive belt. 2. Remove (A) bolts and (B) drive belt tensioner. INSTALLATION 1. Position the drive belt tensioner and install the bolts. 2. Install drive belt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2481 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2482 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2483 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2484 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2485 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2486 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2487 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2488 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2489 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2490 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2491 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2492 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2493 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2494 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2495 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2496 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2497 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2498 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2499 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2500 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2501 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2502 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2503 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2504 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2505 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2506 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2507 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2508 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2509 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2510 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2511 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2512 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2513 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2514 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2515 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2516 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2517 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2518 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2519 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2520 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2521 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2522 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2523 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2524 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2525 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2526 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2527 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2528 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2529 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2530 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2531 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2532 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2533 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2534 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2535 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2536 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2537 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2538 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2539 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2540 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2541 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2542 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2543 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2544 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2545 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2546 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2547 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2548 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2549 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2550 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2551 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2552 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2553 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2554 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2555 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2556 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2557 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2558 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2559 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2560 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2561 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2562 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2563 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2564 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2565 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2566 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2567 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2568 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2569 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2570 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2571 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2572 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2573 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 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. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2574 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 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. 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 the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2575 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 2576 Engine Mount: Specifications TORQUE SPECIFICATIONS Engine Mount to Block Bolts .............................................................................................................................................. 53-72 Nm (38.9-53 inch lbs.) Engine Mount Pivot Bolt .................................................................................................................................................. 68-92 Nm (49.9-67.6 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH Engine Mount: Service and Repair LH REMOVAL 1. Remove the fan shroud. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Raise and support the vehicle. 3. Remove the LH bolt. 4. Loosen the RH bolt. 5. Position a suitable jack under the rear axle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2579 6. Lift the engine with suitable jacks. 7. Remove the bolts and remove the engine mount. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2580 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2581 Engine Mount: Service and Repair RH REMOVAL 1. Remove the fan shroud. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Raise and support the vehicle. 3. Remove the starter motor. 4. Remove the RH bolt. 5. Loosen the LH bolt. 6. Position a suitable jack under the rear axle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2582 7. Lift the engine with suitable jacks. 8. Remove the RH bolts and remove the engine mount. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2583 Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications TORQUE SPECIFICATIONS Belt Idler Pulley Bolt ........................................................................................................................................................... 21.2-28.8 Nm (16-22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications > Page 2587 Idler Pulley: Service and Repair REMOVAL 1. Remove the drive belt. 2. Remove (A) belt idler pulley bolt and (B) belt idler pulley. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure @ 200° F ........................................................................................................................ ..................................................................... 40-70 psi Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 REMOVAL 1. Remove LH exhaust manifold. 2. Remove the oil level dipstick. 3. Remove the bolt. 4. Remove the oil level indicator tube. 5. Replace the O-ring. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair > Page 2595 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2600 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2601 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2602 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2603 Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity ............................................................................................................................................... ............................................................. 6.5L (6.9 Qt) NOTE: Listed capacities are approximate. Check fluid level after filling. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2606 Engine Oil: Fluid Type Specifications Engine Oil Type Type ..................................................................................................................................................... .......................................................................... GF-1 Viscosity .............................................................................................................................................. ...................................................................... 5W-30 NOTE: Must meet Ford Specification M2C-153-F Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair Oil Cooler: Service and Repair REMOVAL WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Raise and support vehicle. 2. Remove the drain plug and drain the engine oil. 3. Drain the coolant. 4. Slide the hose clamps down and disconnect the coolant hoses from the oil cooler. 5. Remove the bolts and remove the oil cooler from the remote oil filter adapter. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Page 2610 1. Position the remote oil filter adapter lines and install the nuts. 2. Position the oil cooler and install the bolt. 3. Install the drain plug. 4. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 5. Fill the engine coolant. 6. Fill the engine with Ford Premium SAE 10W-30 Motor Oil XO-10W-30-BSP, DSP, QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter Oil Filter Adapter: Service and Repair Oil Filter Adapter REMOVAL WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Raise and support the vehicle. 2. Remove the lower radiator hose. 3. Remove the front drive axle assembly. 4. Remove the drain plug and drain the engine oil. 5. If the vehicle does have an oil cooler, remove the oil cooler. 6. Disconnect the oil pressure sender electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2615 7. If the vehicle is equipped with a remote oil filter adapter, remove the nuts and position the remote oil filter adapter aside. 8. Remove the three bolts, the nut and the oil filter adapter. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2616 1. If the vehicle is equipped with a remote oil filter adapter, position the oil filter adapter and install the bolts and the nut. ^ Install a new oil filter adapter gasket. 2. Position the remote oil filter adapter and install the nuts. 3. If the vehicle is not equipped with a remote oil filter adapter, position the oil filter adapter and install the three bolts and the nut. ^ Install a new oil filter adapter gasket. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2617 4. Connect the oil pressure sender electrical connector. 5. If the vehicle is equipped with an oil cooler, install the oil cooler. 6. Install the drain plug. 7. Install the front drive axle assembly. 8. Install the lower radiator hose. 9. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 10. Fill the engine with Ford Premium SAE 10W-30 Motor Oil XO-10-W-30-BSP, DSP, QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2618 Oil Filter Adapter: Service and Repair Remote Adapter REMOVAL WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Raise and support the vehicle. 2. Remove the drain plug and drain the engine oil. 3. If equipped with an oil cooler, remove the two nuts and disconnect the remote oil filter adapter from the oil cooler. 4. If the vehicle is not equipped with an oil cooler disconnect the oil pressure sender electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2619 5. Remove the two nuts and disconnect the remote oil filter adapter. 6. Remove the oil bypass filter. 7. Remove the bolts, and remove the remote oil filter adapter. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2620 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2621 1. Follow the removal procedure in reverse order. ^ Fill the engine with Ford Premium SAE 1OW-30 Motor Oil XO-1OW-30-BSP, DSP, QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair Oil Pan: Service and Repair REMOVAL WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, BACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Raise and support the vehicle. 2. Remove the front drive axle assembly. 3. Remove the drain plug and drain the engine oil. 4. Remove the bolts. 5. Remove the oil pan and oil pan gasket. ^ Inspect oil pan gasket for darnage. ^ Replace if necessary. NOTE: Be careful when removing the oil pan gasket. The oil pan gasket is reusable if it is not damaged. INSTALLATION 1. Clean the mating surfaces. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Page 2625 scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. 2. Apply the silicone at the rear oil seal retainer to cylinder block sealing surface. ^ Use Ford Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. NOTE: If the oil pan and the oil pan gasket are not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. 3. Apply the silicone at the engine front cover to the cylinder block sealing surface. ^ Use Ford Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. NOTE: If the oil pan and the oil pan gasket are not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. 4. Install the oil pan gasket and the oil pan and loosely install the 16 bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Page 2626 5. Tighten the bolts in the sequence shown. ^ Step 1: Tighten to 2 Nm (18 inch lb). ^ Step 2: Tighten to 20 Nm (15 ft/lb). ^ Step 3: Tighten an additional 60 degrees. NOTE: Make sure to tighten the bolts in three steps. 6. Install the front drive axle assembly. 7. Lower the vehicle. 8. Fill the engine with oil. ^ Use Ford Premium SAE 1OW-30 Motor Oil XO-1OW-30-BSP, DPS, QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 REMOVAL 1. Remove the oil pan. 2. Remove the three (A) bolts and the (B) oil pump screen cover and tube. INSTALLATION 1. Clean and inspect the mating surfaces. 2. Install the oil pump screen cover and tube and install the bolts. 3. Install the oil pan. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure @ 200° F ........................................................................................................................ ..................................................................... 40-70 psi Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications TORQUE SPECIFICATIONS Lower Intake to Upper Intake Bolts Tighten the lower intake manifold bolts in two stages, in the sequence shown: Stage 1: 2 Nm (18 inch lbs.). - Stage 2: 8-12 Nm (71-106 inch lbs.). Upper Intake to Cylinder Head Bolts Tighten the bolts in two steps, in the sequence shown. Step 1: 2 Nm (18 inch lb) - Step 2: 20-30 Nm (15-22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal Intake Manifold: Service and Repair Removal WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 1. Disconnect the battery ground cable. 2. Perform preservice procedures. 3. Drain the cooling system. 4. Compress and slide the hose clamp and disconnect the upper radiator hose. 5. Remove the engine Air Cleaner (ACL) and air cleaner outlet tube. 6. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 7. Disconnect the accelerator cable from the accelerator cable bracket. 1 Remove the bolt. 2 Slide the accelerator cable up to remove it from the accelerator cable bracket. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2642 8. Disconnect the accelerator cable from the throttle body cam. 1 Roll the throttle body cam forward. 2 Slide the accelerator cable end from the throttle body cam. 9. Remove the throttle return spring. 10. If equipped, disconnect the speed control actuator cable from the throttle body. 1 Remove the speed control actuator cable to accelerator cable bracket bolt. 2 Disconnect the (A) speed control actuator cable from the (B) throttle body cam and position aside. 11. Disconnect the engine vacuum reservoir hose. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2643 12. Remove the bolt and the brake booster vacuum hose and bracket. 13. Disconnect the connector from the throttle position sensor (TP sensor). 14. Disconnect the following throttle body hose connections: ^ vapor management hose (A) ^ engine vacuum regulator (B) ^ Positive Crankcase Ventilation valve (PCV valve) (C) ^ power brake booster (D) 15. Remove the (A) brake booster vacuum hose bracket nut from the (B) brake booster vacuum hose bracket. 16. Disconnect the fuel lines. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2644 17. Disconnect the following electrical connectors: ^ idle Air Control (IAC) valve ^ Differential Pressure Feedback (DPFE) transducer ^ Engine Vacuum Regulator (EVR) sensor 18. Remove the EGR valve to exhaust manifold tube ^ Disconnect the upper and lower EGR valve to exhaust manifold tube fittings. ^ Disconnect the two DPFE hoses. 19. Disconnect the following vacuum connections: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2645 1 fuel pressure regulator vacuum hose 2 Engine Vacuum Regulator (EVR) hose 3 EGR vacuum hose 4 vapor management valve vacuum hose 20. Disconnect the RH fuel injector electrical connectors. 21. Disconnect the LH fuel injector electrical connectors. 22. Disconnect the water temperature indicator sender wiring. 23. Remove the drive belt. 24. Remove the Generator (GEN). 25. Remove the bolts and the throttle body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2646 26. Disconnect the hose clamp and remove the heater water hose. 27. Remove the studs. 28. Remove the water thermostat. 29. Remove the nine bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2647 30. Remove the upper intake manifold. 1 Lift the intake manifold. 2 Disconnect the Intake Manifold Tuning Valve (IMTV) connector. 3 Remove and discard the upper intake manifold gaskets. 31. Remove the bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2648 32. Separate the upper intake manifold from the lower intake manifold and discard the lower intake manifold gasket. 33. Remove the (A) pushpin from the (B) intake manifold insulator and remove from the (C) lower intake manifold. 34. Remove the (A) bolts from the (B) intake manifold tuning valve and remove the intake manifold tuning valve. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2649 Intake Manifold: Service and Repair Installation 1. Position the intake manifold tuning valve and install the bolts. 2. Install the intake manifold insulator on the lower intake manifold and install the pushpin. 3. Position the lower intake manifold gasket and the upper intake manifold on the lower intake manifold and loosely install the eight bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2650 4. Tighten the bolts in two steps, in the sequence shown. Step 1: 2 Nm (18 inch lb) Step 2: 8-12 Nm (71-106 inch lb) 5. Install the studs. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2651 6. Install the upper intake manifold. ^ Position the upper intake manifold gaskets. ^ Position the upper intake manifold. ^ Loosely install the nine bolts. 7. Connect the intake manifold tuning valve connector. 8. Install the water thermostat. 9. Tighten the bolts in two steps, in the sequence shown. Step 1: 2 Nm (18 inch lb) Step 2: 20-30 Nm (15-22 ft. lbs.) 10. Position the throttle body onto the upper intake manifold and install the bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2652 11. Install the heater water hose and position the clamp. 12. Connect the water temperature indicator sender wiring. 13. Install the generator. 14. Install the drive belt . 15. On 5.4L engines, install the eight ignition coils. 16. Connect the LH fuel injector electrical connectors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2653 17. Connect the RH fuel injector electrical connectors. 18. Connect the following vacuum connections: 1 Fuel pressure regulator vacuum connector 2 Engine vacuum regulator vacuum connector 3 EGR vacuum connector 4 Vapor management valve vacuum connector Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2654 19. Connect the EGR valve to exhaust manifold fittings, and tighten to specification. 20. Connect the following electrical connectors: ^ Idle Air Control Valve (IAC valve) ^ DPFE transducer ^ Engine vacuum regulator sensor 21. Connect the fuel lines. 22. Position the brake booster vacuum hose bracket and install the nut. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2655 23. Install the throttle return spring. 24. Connect the accelerator cable to throttle body cam. 1 Rotate the throttle body cam forward. 2 Slide the accelerator cable into the throttle body cam. 25. Connect the accelerator cable to accelerator cable bracket. 1 Slide the accelerator cable into the accelerator cable bracket. 2 Install the bolt. 26. Install the accelerator control splash shield. 27. Install the air cleaner outlet tube and the engine air cleaner. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2656 28. Install the upper radiator hose and reposition the clamp. 29. Fill the cooling system. 30. Install the engine cover. 31. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications Crankshaft Main Bearing Seal: Specifications TORQUE SPECIFICATIONS Rear Oil Seal Retainer Bolt .................................................................................................................................................... 8-12 Nm (71-107 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications > Page 2665 Crankshaft Main Bearing Seal: Service and Repair REMOVAL 1. Remove the transmission. 2. Remove the oil pan. 3. Remove the flywheel. 4. Use the (A) Rear Crankshaft Slinger Remover and the (B) Slide Hammer to remove the (C) rear oil seal slinger. 5. Use the (A) Rear Crankshaft Seal Remover and the (B) Slide Hammer to remove the (C) rear main seal. 6. If the oil dye leak test reveals a leak behind the retainer, remove the six bolts and the crankcase rear oil seal retainer. INSTALLATION 1. Clean and inspect the mating surface. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: Clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer, failure to follow this procedure can cause future oil leakage. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications > Page 2666 2. Apply silicone around the rear oil seal retainer sealing surface. ^ Use Silicone Gasket and Sealant F6AZ-19562-A or equivalent meeting Ford specification WSE-M4G323-A6. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: ^ If the rear crankshaft seal retaining plate is not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. ^ The silicone must be applied on the groove along the retainer plate. 3. Install the rear oil seal retainer and loosely install the six bolts. 4. Tighten the six rear oil seal retainer bolts in the sequence shown. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications > Page 2667 5. Use the Rear Crankshaft Seal Replacer and the Rear Crankshaft Seal Adapter to install the rear main seal. NOTE: Lubricate the inner lip of the rear crankshaft seal with engine oil meeting Ford specification WSS-M2C153-G. 6. With the Rear Crankshaft Seal Adapter still installed, use the Rear Crankshaft Slinger Replacer and the Rear Crankshaft Seal Replacer to install the rear main seal slinger. 7. Install the flywheel. 8. Install the oil pan. 9. Install the transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications > Page 2668 Crankshaft Main Bearing Seal: Tools and Equipment Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 (V8-281 4.6L SOHC (1998)) 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 2673 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 2674 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 2675 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 (V8-281 4.6L SOHC (1998)) 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 2676 Technical Service Bulletin # 02-1-4 Date: 020121 Engine Head Gasket - Approved Replacement Procedures Article No. 02-1-4 01/21/02 ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or scratches and dents at the head to block mating surfaces. ACTION Refer to the following Service Information for recommended gasket sealing surface preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done successfully utilizing leak detection methods such as a black light dye process. SERVICE PROCEDURE To sum up, a successful leak repair depends on: ^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures ^ Surface preparation and gasket installation using the approved tools, cleaners, and methods ^ Exercising CARE and CLEANLINESS during disassembly/assembly of components ^ Use of genuine Ford OEM replacement parts ^ Use of a Ford Remanufacturer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 499000 Aluminum Cylinder Head - Removal From Engine Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 2677 WARNING ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE BENCHTOP OR DAMAGE WILL OCCUR. NOTE SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN PERIOD. NOTE IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE. Place CLEAN shop towels over the cylinder block bores to prevent further contamination from reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected on the towel can fall on the engine if care is not exercised as it is removed. Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively. Contamination on these surfaces will cause leaks from "shimming" the head even under full head bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak path. Inspection For Damage and Cleaning Procedure The overall straightness of the cylinder head and block face is held within very tight specification. Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary equipment. Machining must meet manufacturer's specification on surface finish quality and be less than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler gauge. If the engine has been overheated the cylinder head may have been damaged or warped. Re-surfacing will not correct this damage. The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm). There must not be any scratches or gouges present, especially those which track to another sealing cavity or to the atmosphere. Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion, and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the surface of any material, which could later interfere with the gasket's sealing ability. WARNING UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT SOLVENT. The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the last torquing procedure either from the plant or a previous field repair. The new head bolt shanks and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole. The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces. To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from the block surface. It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks. The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid contaminants. Any staining of the metal surface is considered normal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 2678 Machining of aluminum heads and blocks is an unacceptable field practice for quality control purposes of flatness and surface finish standards. Removing material will also raise the risk of internal reciprocating components striking each other, as well as changing the emissions calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable. Ford Remanufacturers are authorized to perform this procedure and have the necessary equipment to put the specified surface finish on the head within original factory limits. Installation Onto the Cylinder Block Surface WARNING ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL THEREBY TRIPPING FAULT CODES IN THE PCM. Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was removed successfully from the surrounding areas of the block to head face of the head and the block. Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the gasket surfaces to scrape or bang against other engine parts. The head may pick up material along the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring that the head is fully square, seated, and resting on the block deck in a level condition, install new "torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the intervals specified. Failure to follow these instructions may result in a warped head, and damaged head bolt threads. Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench. Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt the integrity of the bolt head and give a false reading on the final torque value of the fastener. Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was) primed properly and is in a "ready to start" condition with all engine oil galleys having been charged with oil. WARNING DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND STEADILY MAINTAINED. Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks around the gasket joints of the head, front cover, and associated component parts. The vehicle should be road tested within normal guidelines to raise the engine to operating temperature and verify the repair is sound. Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 REMOVAL 1. Remove the crankshaft pulley. 2. Use the (A) Front Cover Seal Remover to remove the (B) front cover seal. INSTALLATION 1. Lubricate the (A) engine front cover and the (B) front oil seal inner lip. ^ Use SAE 50W engine oil meeting Ford specification WSS-M2C153-G. 2. Use the (A) Crankshaft Seal Replacer/Cover Aligner to install the (B) crankshaft front seal into the (C) engine front cover. 3. Install the crankshaft pulley. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2682 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 REMOVAL 1. Remove the valve springs. 2. Remove the valve stem seals. INSTALLATION NOTE: ^ The valve stem seal must be bottomed on the valve seat. ^ Make sure that the garter spring is present in the valve stem seal. 1. Use the (A) Valve Stem Seal Replacer to install the (B) valve stem seals. 2. Install the valve springs. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2686 Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications TORQUE SPECIFICATIONS Camshaft Sprocket Bolt ........................................................................................................................................................ 110-130 Nm (81-95 Ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Page 2691 Camshaft Gear/Sprocket: Testing and Inspection WARNING: TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE VEHICLE, DO NOT OPERATE THE ENGINE WITH THE HOOD OPEN UNTIL THE FAN BLADE HAS FIRST BEEN EXAMINED FOR POSSIBLE CRACKS AND SEPARATION. NOTE: ^ Specifications show the expected minimum or maximum condition. ^ If a component fails to meet the specifications, it is necessary to replace or refinish. If the component can be refinished, wear limits are provided as an aid to making a decision. Any component that fails to meet specifications and cannot be refinished must be replaced. 1. Inspect the chain and the sprockets. ^ Replace as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair Timing Chain NOTE: Ford does not provide a procedure to align the timing components without the OE tools specified. Special Tools Removal CAUTION: Since the engine is not free-wheeling, if the crankshaft or the camshafts are moved in any manner during removal and installation the crankshaft and camshafts must be re-synchronized. These steps are located in Engine; Service and Repair; Assembly Steps 35 to 48. 1. Remove the engine front cover. 2. Remove the crankshaft sensor ring from the crankshaft. 3. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2695 Position the crankshaft with the Crankshaft Holding Tool as shown. 4. Install and fully tighten the Camshaft Holding Tools on both camshafts. 5. Remove the timing chain tensioning system from both timing chains. - Remove the bolts. - Remove the timing chain tensioners. - Remove the timing chain tensioner arms. 6. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinders heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur. CAUTION: Do not remove the Camshaft Holding Tool. Remove the LH and RH timing chains and the crankshaft sprockets. Remove the Crankshaft Holding Tool. - Remove the RH timing chain from the camshaft sprocket. - Remove the RH timing chain and outer crankshaft sprocket from the crankshaft. - Repeat for the LH timing chain and crankshaft sprocket. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2696 7. Remove both timing chain guides. - Remove the bolts. - Remove both timing chain guides. Installation 1. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly. Compress the tensioner plunger, using an edge of a vise. 2. Using a small screwdriver or pick, push back and hold the ratchet mechanism. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2697 3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing. 4. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation. 5. Remove the tensioner from the vise. 6. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks. 7. Install the timing chain guides. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2698 8. CAUTION: Do not turn the engine over with the camshaft positioning tool or damage to the camshaft sprocket or the bolt may occur. Install the Camshaft Positioning Tool. 9. Slightly loosen the camshaft holding tools to allow slight camshaft movement. Rotate the LH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 12 o'clock. Rotate the RH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 11 o'clock. Tighten the Camshaft Holding Tools to maintain camshaft pre-positioning. 10. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur. CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and/or valve damage can occur. Position the crankshaft with the Crankshaft Holding Tool. 11. Remove the Crankshaft Holding Tool. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2699 Fig. 26 Crankshaft Sprocket Position 12. NOTE: Crankshaft sprockets are identical. They may only be installed one way. Refer to the illustration for correct crankshaft sprocket installation. If removed, install LH an RH crankshaft sprockets. 13. Install the LH timing chain onto the crankshaft sprocket, aligning the one copper (marked) link on the timing chain with the slot on the crankshaft sprocket. 14. NOTE: Make sure the upper half of the timing chain is below the tensioner guide dowel. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment Position the LH timing chain on the camshaft sprocket with the two copper (marked) chain links and the camshaft sprocket timing mark aligned. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2700 15. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket. 16. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment with the Camshaft Positioning Tool. Position the RH timing chain on the camshaft sprocket. Make sure the two copper-colored links align with the camshaft sprocket timing mark. 17. Position the LH and RH timing chain tensioner arms on the dowel pins. Position the timing chain tensioner assemblies, and install the timing bolts. 18. Remove the RH and LH pins from the timing chain tensioner assembly. 19. Remove the Camshaft Holding Tool. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2701 20. As a post-check, verify proper alignment of all timing marks. 21. Position the crankshaft sensor ring on the crankshaft. 22. Apply a bead of silicone along the cylinder head-to-block surface and the oil pan-to-block surface. - Use Silicone Gasket and Sealant F6AZ-19562-A or equivalent meeting Ford specification WSE-M4G323-A6. 23. Install the engine front cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair Timing Chain Tensioner: Service and Repair Timing Chain Tensioner The Manufacture doesn't provide a timing chain tensioner removal and installation procedure. Please refer to timing chain service and repair. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve .................................................................................................................. .................................................. 7.75 Nm (68.6 Lb/In) Fuel Pressure Relief Valve Cap ..................... ........................................................................................................................................... 0.6 Nm (5.3 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 2710 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE 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. 1. Perform the fuel pressure release procedure. 2. Remove the (A) fuel pressure relief valve with the (B) fuel pressure relief valve cap. INSTALLATION 1. Install fuel pressure relief valve. 2. Install the fuel pressure relief valve cap. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 680 - 830 RPM Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet engine Air Cleaner (ACL) aside. 2. Remove the (A) air cleaner element from the (B) open end of the inlet engine air cleaner. INSTALLATION 1. Install the air cleaner element. 2. Position the engine air cleaner aligning the alignment tab. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet engine air cleaner has an alignment tab which fits into a slot on the outlet engine air cleaner. This ensures a good seal and keeps unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2718 3. Close the air cleaner clamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 EFI/CFI Fuel Pressure Gauge WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place the fuel in a suitable container. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 2726 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 2727 Firing Order 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order Firing Order: 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair REMOVAL CAUTION: Spark plug wires must be connected to the proper ignition coil terminal and spark plug. Mark the spark plug wire locations. 1. Grasp the spark plug boot firmly and use a twisting, pulling motion to disconnect the spark plug wires from the spark plugs. 2. Squeeze the locking tabs and disconnect the spark plug wire from the ignition coil. INSTALLATION 1. Apply Silicone Brake Caliper Grease Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire boots. 2. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Torque ............................................................................................................................... ............................................. 9-20 Nm (80-178 Lb/In) Spark Plug Gap ............................................... ....................................................................................................................... 1.32-1.42 mm (0.052-0.056 in) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 2739 Spark Plug: Specifications Torque Spark Plug Torque ............................................................................................................................... ............................................. 9-20 Nm (80-178 Lb/In) Spark Plug Gap ............................................... ....................................................................................................................... 1.32-1.42 mm (0.052-0.056 in) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2740 Spark Plug: Application and ID RH Original Spark Plug ....................................................................................................................... ........................................................ AWSF32PG (a) LH Original Spark Plug ..................................... ............................................................................................................................................. AWSF32P (a) Replacement Spark Plug (Either Side) ......................................................................................................................................................... AWSF32PP (a) (a) If a spark plug is removed for examination, it must be reinstalled in the same cylinder. If a new spark plug needs to be installed, use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2741 Spark Plug: Service and Repair REMOVAL CAUTION: Spark plug wires must be connected to the proper ignition coil terminal and spark plug. Mark the spark plug wire locations. NOTE: Use compressed air to remove any debris from the spark plug well before removing the spark plugs. 1. Grasp the spark plug boot firmly and use a twisting, pulling motion to disconnect the spark plug wires from the spark plugs. 2. Remove the spark plugs. NOTE: Remove any foreign debris from the spark plug wells with compressed air. 3. Inspect the spark plug. INSTALLATION 1. Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire boots. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2742 2. Adjust the spark plug gap as required. 3. Install the spark plugs. 4. Connect the spark plug wires. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test Compression Check: Testing and Inspection Compression Test 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as Compression Tester in No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, use the auxiliary starter switch to 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test > Page 2748 Compression Check: Testing and Inspection Interpreting Compression Readings 1. If compression improves considerably, the piston rings require service. 2. If compression does not improve, the valves are sticking or seating improperly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on the piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil and/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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test > Page 2749 Compression Check: Testing and Inspection Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Use the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil SAE 1OW-40XO-1OW40-QSP meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer does not indicate whether this vehicle has adjustable or non-adjustable valves. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications Drive Pulley: Specifications DRIVE RATIO Pump Pulley Ratio ............................................................................................................................... ......................................................................... 1.3 TORQUE SPECIFICATIONS Water Pump Pulley Bolts ........................................................................................................................................................... 20-30 Nm (15-22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement Technical Service Bulletin # 98B33 Date: 990401 Campaign - Coolant/Cylinder Head Replacement OWNER NOTIFICATION PROGRAM 98B33 Certain 1997 and 1998 Expedition, F-150 and 1998 Navigator vehicles equipped with 4.6L and 5.4L engines for inspection of coolant and, if necessary, replacement of engine cylinder heads ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Requirements ^ Attachment IIIA ^ A - Coolant Test Instructions ^ Attachment IIIB ^ B - Cylinder Head Replacement Instructions ^ Attachment IV ^ Copy of Lincoln Commitment Special Handling Procedure Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2766 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2767 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles on the enclosed list. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2768 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with this special handling procedure. CLAIMS Enter claims using DWE. See ACESII Manual. To claim for the "Lincoln Commitment Special Handling", follow the instructions on Attachment IV. OWNER REFUNDS See ACESII Manual, Section 3 for submission procedures. For owner-paid repairs of cracked cylinder heads or damage directly related to cracked cylinder heads made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from servicing dealer), enter using DWE: RENTAL CARS If cylinder head replacement is necessary, Ford will pay for a loaner or rental vehicle except for fuel and insurance which will be at the owner's expense. Do not provide a rental vehicle while cylinder heads are on order. Rentals should be provided only while the vehicle is at the dealership for cylinder head replacement. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days vehicle was used in the Miscellaneous Expense area of the recall claim. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2769 COOLANT TESTER Coolant concentrate test kits will be sent at no charge 10 dealers with affected vehicles. Additional stock of testers is limited, but testers may be ordered from the Recall Hotline 1-800-325-5621. PARTS REQUIREMENTS Parts Ordering Information Cylinder head kits can be ordered by calling the Recall Hotline at 1-800-325-5621. The kits listed contain all parts necessary for cylinder head replacement except coolant, oil and oil filter: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2770 DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 98B33 ^ Labor Operation: (see Labor Allowances) See the ACESII manual for detailed instructions. Attachment IIIA - A-Coolant Test Instructions SERVICE PROCEDURE 1. Open hood. 2. Remove coolant recovery bottle cap. 3. Run engine until normal operating temperature (thermostat open) is reached. 4. Insert supplied glycol tester (Thexton 106) into coolant recovery bottle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2771 5. Fill tester to level shown in Figure 1. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2772 ^ If five (5) or less discs float, refer to Figure 2, no service action is needed. Return vehicle to customer. ^ If all six (6) discs float, indicating "NOT SAFE" glycol condition, see Figure 2, call Recall Hotline at 1-800-325-5621 to order cylinder head kit. Perform cylinder head replacement, when kit arrives. Removal Removal 1. On air suspension equipped vehicles, turn air suspension switch, located in the RH kick panel area, to the OFF position. 2. Install memory saver, then disconnect battery negative cable. 3. Remove shield covering throttle body assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2773 4. Disconnect mass air flow (MAF) sensor electrical connector. Refer to Figure 1. 5. Disconnect intake air temperature (IAT) sensor electrical connector. Refer to Figure 1. 6. Remove air cleaner half and clean air tube as an assembly. See Figure 1. 7. Remove remaining half of air cleaner. 8. Disconnect accelerator cable, speed control cable and return spring from throttle body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2774 9. Remove accelerator cable bracket from intake manifold, then unclip cables from clip on power steering reservoir bracket. See Figure 2. Position cable assembly aside. 10. On 4.6L engines, proceed as follows: ^ Disconnect vapor management valve (VMV) vacuum line at rear of throttle body adapter. Refer to Figure 3. ^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 3. ^ Disconnect PCV hose at rear of throttle body adapter. Refer to Figure 3. ^ Remove brake booster vacuum line retainer at EGR valve. Disconnect vacuum line at throttle body adapter. See Figure 3. Position line aside. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2775 ^ Disconnect vapor management valve (VMV) vacuum line. Refer to Figure 4. ^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 4. ^ Disconnect EGR valve vacuum line. Refer to Figure 4. ^ Disconnect EVR solenoid vacuum line. See Figure 4. ^ Position vacuum harness away from engine. 11. On 5.4L engines, proceed as follows: ^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 5. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2776 ^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle. 12. Raise vehicle. 13. Disconnect EGR tube from exhaust manifold. 14. Disconnect oil pressure switch electrical connector. See Figure 6. 15. Disconnect crankshaft position (CKP) sensor electrical connector. See Figure 7. 16. On 4X2 models, disconnect A/C clutch electrical connector. 17. Drain coolant from radiator. NOTE: Do not remove right side cylinder block coolant drain plug. 18. Remove left side cylinder block coolant drain plug. Allow coolant to completely drain. 19. Install cylinder block coolant drain plug. Tighten plug to 16-24 Nm (12-17 lb-ft). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2777 20. Drain engine oil. Do not final tighten drain plug at this time, as it will be removed again. 21. Lower vehicle. NOTE: The best access to the A/C electrical connector is through the wheel well. 22. On 4X4 models, disconnect A/C clutch electrical connector. 23. Mark and disconnect DPFE transducer hoses from EGR tube. 24. Disconnect EGR tube from EGR valve, then remove EGR tube from vehicle. 25. On 4.6L engines, proceed as follows: ^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 8. ^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2778 ^ Disconnect EVR solenoid electrical connector. Refer to Figure 9. ^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 9. ^ Disconnect Idle Air Control (IAC) motor electrical connector. Refer to Figure 9. ^ Disconnect DPFE transducer electrical connector. See Figure 9. ^ Disconnect left side coil pack electrical connector. Refer to Figure 10. ^ Disconnect camshaft position (CMP) sensor electrical connector. Refer to Figure 10. ^ Disconnect left side radio interference suppressor electrical connector. See Figure 10. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2779 ^ Disconnect ignition wires from left side coil pack. ^ Remove left side coil pack from vehicle. ^ Unclip left side fuel charge harness from cam cover studs. Refer to Figure 11. ^ Unclip ignition wire separators from left cam cover studs. See Figure 11. ^ Disconnect ignition wires from left side spark plugs. Route ignition wires to front of engine. ^ Disconnect left side fuel injector electrical connectors. 26. On 5.4L engines, proceed as follows: ^ Disconnect Vapor Management Valve (VMV) vacuum line. Refer to Figure 12. ^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 12. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2780 ^ Disconnect EGR valve vacuum line. Refer to Figure 12. ^ Disconnect EVR solenoid vacuum line. See Figure 12 ^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 13. ^ Position vacuum harness away from engine. ^ Disconnect VMV purge line at top of throttle body adapter. See Figure 13. ^ Disconnect brake booster vacuum line from throttle body adapter. ^ Remove brake booster vacuum line bracket from intake manifold. Position vacuum line assembly away from intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2781 ^ Disconnect Idle Air Control (IAC) motor electrical connector. See Figure 14. ^ Disconnect left side radio interference suppressor electrical connector. Refer to Figure 15. ^ Disconnect DPFE transducer electrical connector. Refer to Figure 15. ^ Disconnect EVR solenoid electrical connector. Refer to Figure 15. ^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 15. ^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2782 ^ Disconnect camshaft position (CMP) sensor electrical connector. See Figure 16. ^ Disconnect ignition coil electrical connectors from left side of engine. Refer to Figure 17. ^ Disconnect fuel injector electrical connectors from left side of engine. See Figure 17. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2783 ^ Remove left side fuel charge harness from cam cover studs, then position harness away from cam cover. See Figure 18. ^ Remove left side ignition coils from vehicle. WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 27. Relieve fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on EFI/CFI fuel pressure gauge. ^ Remove fuel pressure gauge and reinstall schrader valve cap. 28. Disconnect fuel lines from fuel manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2784 29. Remove junction block splash shield. See Figure 19. 30. Disconnect positive leads from starter relay. Refer to Figure 20. 31. Unclip two (2) mega-fuses from bracket. Refer to Figure 20. 32. Disconnect two (2) 42-pin bulkhead electrical connectors. Refer to Figure 20. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2785 33. Remove both bulkhead electrical connector halves from bracket. See Figure 20. 34. Disconnect 16-pin electrical connector. Refer to Figure 21. 35. Disconnect single-pin electrical connector. Refer to Figure 21. 36. Remove junction block bracket. See Figure 21. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2786 37. Remove heater supply hose from vehicle. Refer to Figure 22. 38. Disconnect heater return hose from heater core fitting. Then position hose away from right cam cover. Refer to Figure 22. 39. Remove ground strap to bulkhead retaining bolt, then unwrap ground strap from fuel manifold. See Figure 22. 40. Remove PCV valve and line from vehicle. 41. On 4.6L engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2787 ^ Disconnect right side coil pack electrical connector. Refer to Figure 23. ^ Disconnect right side radio interference suppressor electrical connector. Refer to Figure 23. ^ Disconnect ignition wires from right side coil pack. See Figure 23. ^ Remove right side coil pack from vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2788 ^ Unclip right side fuel charge harness from cam cover studs. Refer to Figure 24. ^ Unclip ignition wire separators from right cam cover studs. See Figure 24. ^ Disconnect ignition wires from right side spark plugs. Route ignition wires to front of engine. ^ Disconnect right side fuel injector electrical connectors. ^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. Refer to Figure 25. ^ Disconnect water temperature sender electrical connector. Refer to Figure 25. ^ Remove tie strap retaining alternator wiring harness to fuel manifold. See Figure 25. 42. On 5.4L engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2789 ^ Disconnect right side radio interference suppressor. See Figure 26. ^ Disconnect ignition coil electrical connectors from right side of engine. Refer to Figure 27. ^ Disconnect fuel injector electrical connectors from right side of engine. See Figure 27. ^ Remove right side fuel charge harness from cam cover studs, then position harness away from cam cover. ^ Remove right side ignition coils from vehicle. ^ Remove tie strap retaining alternator wiring harness to fuel manifold. 43. Disconnect upper radiator hose from thermostat housing. 44. Remove drive belt. 45. Remove alternator and mounting bracket as an assembly. The ignition wires and the alternator wiring harness will also be removed with the alternator assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2790 46. Disconnect cylinder head temperature (CHT) sensor electrical connector. Refer to Figure 28. 47. Disconnect tuning valve electrical connector. See Figure 28. 48. Remove the intake manifold retaining bolts. See Figure 29. 49. Remove intake manifold from vehicle. 50. Remove and discard intake manifold gaskets. NOTE: On 5.4L engine, cam cover bolts cannot be separated from cam cover. NOTE: Be careful not to damage cam cover gaskets, as they will be reused. Remove both camshaft covers. 51. Remove both camshaft covers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2791 52. Disconnect heater return hose from coolant tube, then remove heater hose from vehicle. Refer to Figure 30. 53. Remove retainers securing routing bracket to rear of right-hand cylinder head, then remove routing bracket and ground strap. Refer to Figure 30. 54. Remove coolant tube retainers securing coolant tube to rear of right hand cylinder head, then remove coolant tube. See Figure 30. 55. Remove jack handle from radiator air deflector. 56. Remove air deflector on top of radiator. 57. Disconnect coolant recovery hose from radiator. 58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, remove cooling fan and clutch assembly. 59. Remove cooling fan shroud. 60. On automatic transmission models, disconnect transmission lines from radiator. 61. Disconnect lower radiator hose from radiator. 62. Remove radiator support brackets, then the radiator. 63. Remove water pump pulley, then the water pump. 64. On 4.6L and 5.4L Windsor engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2792 ^ Remove two (2) upper power steering pump retaining bolts. Refer to Figure 31. ^ Raise vehicle. ^ Remove one (1) lower power steering pump retaining bolt, then position power steering pump away from front engine cover. See Figure 31. 65. On Romeo engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2793 ^ Remove two (2) upper power steering pump retaining bolts. See Figure 32. ^ Raise vehicle. NOTE: One of the following bolts cannot be completely removed from the power steering pump due to clearance with the power steering line. ^ Remove two (2) lower power steering pump retaining bolts, then position power steering pump away from front engine cover. See Figure 33. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2794 66. Remove four (4) front oil pan bolts. See Figure 34. 67. Lower vehicle. 68. Using Crankshaft Damper Remover T58P-6316-D, remove crankshaft pulley. 69. Using Front Cover Seal Remover T74P-6700-A, remove engine front cover oil seal. 70. Remove idler pulley from right side of engine front cover. This pulley blocks a front cover bolt. 71. Remove engine front cover retainers. See Figure 35. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2795 72. Remove engine front cover from engine. See Figure 36. 73. Remove crankshaft sensor ring. 74. Using Crankshaft Holding Tool T93P-6303-A, rotate crankshaft until crankshaft keyway points to the 12 o'clock position. See Figure 37. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2796 75. Install Camshaft Holding Tool T96T-6256-B, on each camshaft. See Figure 38 for holding tool placement. 76. Remove both timing chain tensioners. See Figure 39. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2797 77. Remove both timing chain tensioner guides. See Figure 40. 78. Lift right-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. Refer to Figure 41. 79. Lift left-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. See Figure 41. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2798 80. Remove both timing chain guides. See Figures 42 and 43. NOTE: Removal of this wheel opening molding screw is necessary to access all screws for the fender splash shield. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2799 81. On 4X4 models, remove one (1) screw shown in Figure 44, from both wheel opening moldings. 82. Remove both front fender splash shields. See Figure 45. 83. Raise vehicle. 84. Disconnect exhaust Y-pipe from exhaust manifolds. 85. Slightly lower vehicle. Exhaust manifold retainers will be accessed through the wheel well opening. 86. Remove left side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged. 87. Loosen engine oil indicator tube; then turn tube away from cylinder head. Removal of indicator tube is not necessary. 88. Remove right side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged. 89. Remove retainer securing transmission indicator tube to right cylinder head if equipped. NOTE: Cylinder head bolts that are under the camshaft holding tools cannot be completely removed from the head due to clearance with the holding tool. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2800 Completely loosen these bolts. 90. Remove both cylinder heads. See Figure 46. Discard all cylinder head bolts. 91. Remove and discard both cylinder head gaskets. 92. On Romeo engines, proceed as follows: ^ Remove spark plugs from right cylinder head. ^ Remove camshaft sprocket from right side camshaft. ^ Remove Camshaft Holding Tool from right side camshaft. ^ Install camshaft sprocket on new right side camshaft. Do not final tighten retaining bolt at this time. ^ Remove spark plugs from left cylinder head. ^ Remove camshaft sprocket from left side camshaft. ^ Remove Camshaft Holding Tool from left side camshaft. ^ Install camshaft sprocket on new left side camshaft. Do not final tighten retaining bolt at this time. ^ Remove power steering reservoir bracket and CHT sensor from left cylinder head. 93. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Remove Camshaft Holding Tools from both camshafts. ^ Remove power steering reservoir bracket and Cylinder Head Temperature sensor from left cylinder head. ^ Remove all eight (8) spark plugs from cylinder heads. 94. Clean the following gasket surfaces: ^ Cylinder block to cylinder head. ^ Engine front cover. ^ Water pump. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2801 ^ Intake manifold. ^ Both cam covers. Installation 1. On all cylinder heads, install one (1) pipe plug into the rear of each cylinder head in locations shown in Figure 47. 2. On 4.6L Romeo engines, install one (1) pipe plug into the front of each cylinder head in locations shown in Figure 48. 3. Install CHT sensor to left cylinder head. Tighten sensor to 24-28 Nm (17-20 lb-ft). 4. Install power steering bracket to left cylinder head. 5. Install all spark plugs (both sides). Tighten plugs to 9-20 Nm (81-178 lb-in). 6. Install right cylinder head gasket. 7. Install right cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2802 8. Tighten right cylinder head bolts in sequence shown in Figure 49 in the following three (3) stages: ^ Stage 1: 37-43 Nm (27-32 lb-ft). ^ Stage 2: Rotate 85-95 degrees. ^ Stage 3: Rotate 85-95 degrees. 9. Lubricate all camshaft journals. 10. Install left cylinder head gasket. 11. Install left cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2803 12. Tighten left cylinder head bolts in sequence shown in Figure 50 in the following three (3) stages: ^ Stage 1: 37-43 Nm (27-32 lb-ft). ^ Stage 2: Rotate 85-95 degrees. ^ Stage 3: Rotate 85-95 degrees. 13. Lubricate all camshaft journals. 14. Raise vehicle. 15. Install transmission indicator tube retainer to right cylinder head if equipped. Tighten retainer to 18-23 Nm (14-16 lb-ft). 16. Install right side exhaust manifold gasket. NOTE: Due to clearance, the exhaust system Y-pipe mounting flange cannot be positioned on the exhaust manifold outlet after the exhaust manifold is installed on the cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2804 17. Install right side exhaust manifold and gasket. Align exhaust system Y-pipe mounting flange with the studs in the exhaust manifold outlet before completely installing the exhaust manifold on the cylinder block. Tighten right side exhaust manifold retainers in sequence shown in Figure 51 to 18-22 Nm (13-16 lb-ft). 18. Position engine oil indicator tube in installed position. 19. Install left side exhaust manifold and gasket. Tighten retainers in sequence shown in Figure 52 to 18-22 Nm (13-16 lb-ft). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2805 20. Remove oil pan drain plug. Completely drain any fluid (oil, coolant) from oil pan. Reinstall drain plug, tightening to 11-16 Nm (98-143 lb-in). 21. Replace oil filter. 22. Install exhaust system Y-pipe to exhaust manifolds. Tighten retainers to 34-46 Nm (25-34 lb-ft). 23. Lower vehicle. 24. Install both fender splash shields. Tighten retainers to 10-13 Nm (89-115 lb-in). 25. On 4X4 models, install one screw removed from both wheel opening moldings. 26. On Romeo engines, proceed as follows: ^ Using socket on camshaft sprocket bolt, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53. ^ Using socket on camshaft sprocket bolt, rotate right camshaft until timing mark is in 11 o'clock position. Refer to Figure 53. 27. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Using Camshaft Positioning Tool T96T-6256-AR, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53. ^ Using Camshaft Positioning Tool T96T-6256-AR, rotate right camshaft until timing mark is in 11 o'clock position. See Figure 53. ^ Install Camshaft Holding Tool T96T-6256-B on each camshaft. 28. On Romeo engines, tighten both camshaft sprocket bolts to 110-130 Nm (81-95 lb-ft). CAUTION Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and/or valve damage can occur. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2806 29. Rotate crankshaft using Crankshaft Holding Tool T93P-6303-A. See Figure 54. Fully install holding tool. This will position crankshaft keyway to about 10:30 position. 30. Remove Crankshaft Holding Tool. 31. Compress timing chain tensioner plunger as follows: CAUTION Do not compress the ratchet assembly. This will damage the ratchet assembly. CAUTION Use protective vocers over jaws of vise to prevent damage to tensioner. ^ Compress tensioner plunger using edge of vise. See Figure 55. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2807 ^ Using small screwdriver or pick, push back and hold ratchet mechanism. See Figure 56. ^ While holding ratchet mechanism, push ratchet arm back into tensioner housing. See Figure 57. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2808 ^ Install paper clip into hole in tensioner housing. This will hold ratchet assembly and plunger in during installation. See Figure 58. ^ Remove tensioner from vise. ^ Repeat procedure for second tensioner. 32. If copper links are not visible, mark one (1) link on each end of the timing chain. One link will be an inside link. Use these marks as timing marks. See Figure 59. Repeal this step for other timing chain, if necessary. 33. Install right side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in). 34. Install left side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in). 35. Install timing chains and sprockets as follows: ^ Position left side crankshaft sprocket in left side timing chain. Make sure crankshaft sprocket hub is facing outward. Align mark on timing chain with corresponding dot on crankshaft sprocket. ^ Slide left side sprocket and chain on crankshaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2809 ^ Position left side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned. ^ Position right side crankshaft sprocket in right side timing chain. Make sure crankshaft sprocket hub is facing inward. Align mark on timing chain with corresponding dot on crankshaft sprocket. ^ Slide right side sprocket and chain on crankshaft. ^ Position right side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned. ^ Make sure marks on timing chain are lined up with corresponding dots on crankshaft and camshaft sprockets. See Figure 60. ^ Make sure right side crankshaft sprocket is in front of left side crankshaft sprocket with hubs facing each other. See Figure 61. 36. Install right and left timing chain tensioner guides. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2810 37. Install right and left timing chain tensioners. Tighten retainers to 20-30 Nm (15-20 lb-ft). 38. Remove paper clips from both timing chain tensioners. 39. Remove both camshaft holding tools. 40. Install crankshaft sensor ring. 41. Install engine front cover as follows: NOTE: The engine front cover must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, along head to block surface and oil pan to block surface. See Figure 62. ^ Using new gasket, install engine front cover. Align cover with cylinder block dowel. ^ Loosely install engine front cover bolts and stud bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2811 ^ Tighten first five (5) engine front cover bolts in sequence shown in Figure 63, to 20-30 Nm (15-22 lb-ft). ^ Tighten remaining ten (10) engine front cover bolts in sequence shown in Figure 64. On Romeo engines, tighten bolts to 20-30 Nm (15-22 lb-ft). On 4.6L and 5.4L Windsor engines, tighten bolts to 40-55 Nm (29-40 lb-ft). 42. Install right side idler pulley. Tighten retainer to 20-30 Nm (15-22 lb-ft). 43. Using clean engine oil, lubricate engine front cover oil seal inner lip. 44. Using Crankshaft Seal Replacer/Aligner T88T-6701-A, install front cover oil seal. 45. Install crankshaft pulley as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2812 NOTE: The crankshaft pulley must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to woodruff key slot on crankshaft pulley. See Figure 65. ^ Using Crankshaft Damper Replacer T74P-6316-B, install crankshaft pulley. ^ Loosely install crankshaft pulley bolt. ^ Tighten crankshaft pulley bolt to 90 Nm (66 lb-ft). ^ Loosen crankshaft pulley bolt one (1) full turn. ^ Tighten crankshaft pulley bolt to 47-53 Nm (34-39 lb-ft). ^ Tighten crankshaft pulley bolt an additional 85-90 degrees (1/4 turn). 46. On Romeo engines, proceed as follows: ^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft). ^ Raise vehicle. ^ Install two (2) power steering pump lower retaining bolts. Tighten bolt to 20-30 Nm (15-22 lb-ft). 47. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft). ^ Raise vehicle. ^ Install power steering pump lower retaining bolt. Tighten bolt to 20-30 Nm (15-22 lb-ft). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2813 48. Loosely install four (4) front oil pan bolts. Tighten bolts in sequence shown in Figure 66, in the following two (2) stages: ^ Stage 1: 20 Nm (15 lb-ft). ^ Stage 2: Rotate an additional 60 degrees. 49. Lower vehicle. 50. Using coolant, lubricate new water pump O-ring seal. Install seal on water pump. 51. Install water pump. Tighten retainers in sequence shown in Figure 67, to 20-30 Nm (15-22 lb-ft). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2814 52. Install water pump pulley. Tighten retainers in sequence shown in Figure 68, to 20-30 Nm (15-22 lb-ft). 53. Install radiator. Make sure radiator is sitting on mounting insulators. 54. Install radiator supports. Tighten retainers to 25-35 Nm (18-26 lb-ft). 55. Connect lower radiator hose to radiator. 56. On automatic transmission models, connect transmission cooler lines to radiator. Tighten lines to 16-24 Nm (12-18 lb-ft). 57. Install cooling fan shroud. Tighten retainer 108-10 Nm (71-89 lb-in). 58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, install cooling fan and clutch assembly. 59. Connect coolant recovery hose to radiator. 60. Install air deflector on top of radiator. 61. Install jack handle on radiator air deflector. 62. Using clean coolant, lubricate coolant tube O-ring seal. Install coolant tube. Tighten retainers on rear of right cylinder head to 40-55 Nm (29-40 lb-ft). NOTE: Make sure left side fuel charge harness is between routing bracket and cylinder head. 63. Install routing bracket and ground strap to rear of right cylinder head. Tighten retainers to 9-12 Nm (80-107 lb-in). 64. Install heater return hose to coolant tube. 65. Install cam cover gaskets on both cam covers. NOTE: The cam cover must be installed within four (4) minutes after applying silicone. 66. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2815 67. Install right side cam cover. Tighten retainers in sequences shown in Figures 69 and 70, to 8-12 Nm (71-107 lb-in). NOTE: The cam cover must be installed within four (4) minutes after applying silicone. 68. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2816 69. Install left side cam cover. Tighten retainers in sequences shown in Figures 71 and 72, to 8-12 Nm (71-107 lb-in). 70. Install new intake manifold gaskets. 71. Install intake manifold (including thermostat housing). Tighten bolts in sequence shown in Figure 73, in the following two (2) stages: ^ Stage 1: 2 Nm (18 lb-in). ^ Stage 2: 20-30 Nm (15-22 lb-ft). 72. Loosely position left side fuel charge harness on cam cover. 73. Connect tuning valve electrical connector. 74. Connect CHT sensor electrical connector. 75. Install alternator assembly. Tighten front alternator bolts to 21-28 Nm (15-21 lb-ft). Tighten alternator bracket bolts to 9-12 Nm (80-106 lb-in). 76. Install drive belt. 77. Using tie strap, retain alternator wiring harness to fuel manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2817 78. On 4.6L engines, proceed as follows: ^ Loosely position right side fuel charge harness on cam cover. ^ Connect water temperature sensor electrical connector. ^ Connect ECT sensor electrical connector. ^ Connect right side ignition wires to spark plugs. ^ Clip ignition wire separators to right cam cover. ^ Connect right side fuel injector electrical connectors. ^ Clip right side fuel charge harness to cam cover. ^ Install right side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft). ^ Connect ignition wires to right side coil. ^ Connect right side radio interference suppressor electrical connector. ^ Connect right side coil pack electrical connector. 79. On 5.4L engines, proceed as follows: ^ Install right side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in). ^ Position right side fuel charge harness on cam cover studs. ^ Connect right side fuel injector electrical connectors. ^ Connect right side ignition coil electrical connectors. ^ Connect right side radio interference suppressor. 80. Install PCV valve and line assembly. 81. Connect ground strap to bulkhead. 82. Connect heater return hose to heater core. 83. Install heater supply hose. 84. Install junction block bracket. Tighten retainers securely. 85. Connect single-pin electrical connector. 86. Connect 16-pin electrical connector. 87. Install both 42-pin bulkhead electrical connector halves to junction block bracket. 88. Connect both 42-pin bulkhead electrical connectors. Tighten retainers to 4-5 Nm (35-44 lb-in). 89. Clip two (2) mega-fuses to junction block bracket. 90. Connect positive leads to starter relay. 91. Install junction block bracket splash shield. 92. Connect fuel lines to fuel manifold. 93. On 4.6L engines, proceed as follows: ^ Connect left side ignition wires to spark plugs. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2818 ^ Clip ignition wire separators to left cam cover. ^ Connect left side fuel injector electrical connectors. ^ Clip left side fuel charge harness to cam cover. ^ Install left side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft). ^ Connect ignition wires to left side coil. ^ Connect left side radio interference suppressor electrical connector. ^ Connect CMP electrical connector. ^ Connect left side coil pack electrical connector. ^ Connect DPFE transducer electrical connector. ^ Connect IAC motor electrical connector. ^ Connect TP sensor electrical connector. ^ Connect EVR solenoid electrical connector. ^ Connect crankcase vent tube to left cam cover. ^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft). 94. On 5.4L engines, proceed as follows: ^ Install left side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in). ^ Connect left side fuel injector electrical connectors. ^ Connect left side ignition coil electrical connectors. ^ Connect ECT sensor electrical connector. ^ Connect TP sensor electrical connector. ^ Connect EVR solenoid electrical connector. ^ Connect DPFE transducer electrical connector. ^ Connect left side radio interference suppressor electrical connector. ^ Connect IAC motor electrical connector. ^ Connect brake booster vacuum line to throttle body adapter, then install brake booster vacuum line bracket to intake manifold. ^ Connect VMV purge line to top of throttle body adapter. ^ Position vacuum harness on top of motor. ^ Connect vacuum tap to right side of throttle body adapter. ^ Connect EVR solenoid vacuum line. ^ Connect EGR valve vacuum line. ^ Connect fuel pressure regulator vacuum line. ^ Connect vapor management valve vacuum line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2819 95. Connect EGR tube to EGR valve. Hand-tighten fitting at this time. 96. Connect DPFE transducer hoses to EGR tube. 97. On 4X4 models, connect A/C clutch electrical connector. 98. Raise vehicle. 99. Connect EGR tube to exhaust manifold. Tighten fitting to 35-45 Nm (26-33 lb-ft). 100. On 4X2 models, connect A/C clutch electrical connector. 101. Connect CKP sensor electrical connector. 102. Connect oil pressure switch electrical connector. 103. Lower vehicle. 104. Final tighten EGR tube to valve to 35-45 Nm (26-33 lb-ft). 105. On 4.6L engines, proceed as follows: ^ Loosely position vacuum harness over engine. ^ Connect EVR solenoid vacuum line. ^ Connect EGR valve vacuum line. ^ Connect fuel pressure regulator vacuum line. ^ Connect vapor management valve vacuum line. ^ Position brake booster vacuum line in installed position. Connect line to tap on throttle body adapter. Tighten line retainer at EGR valve to 8-12 Nm (71-106 lb-in). ^ Connect vacuum tap on right side of throttle body adapter. ^ Connect VMV vacuum line at rear of throttle body adapter. 106. On 5.4L engines, proceed as follows: ^ Connect crankcase vent tube to left cam cover. ^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft). 107. Position accelerator/speed control cables on top of engine. Secure cables to clip on power steering reservoir. 108. Install accelerator cable bracket to intake manifold. Tighten retainer to 6-8 Nm (53-71 lb-in). 109. Connect accelerator cable, speed control cable and return spring to throttle body. 110. Connect upper radiator hose to thermostat housing. 111. Install rear half of air cleaner. 112. Install front half of air cleaner and clean air lube. 113. Connect IAT and MAF electrical connectors. 114. Install throttle body shield. 115. Connect battery negative cable. 116. Remove memory saver. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2820 117. Fill engine with new engine oil. 118. Fill cooling system as follows: ^ Add 50/50 coolant mixture to radiator coolant recovery reservoir. ^ Install radiator cap. ^ Move temperature blend selector to full warm position. ^ Run engine until it reaches operating temperature. ^ Add 50/50 coolant mixture to radiator coolant recovery reservoir until the coolant level is between the "COOLANT FILL LEVEL" marks. ^ Turn off engine and allow cooling system to cool. ^ Repeat bulleted steps until radiator coolant recovery reservoir level remains in between fill level marks when engine is cool. 119. On air suspension equipped models, turn air suspension switch to ON position. 120. Check engine for proper operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2821 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2822 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2823 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2824 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2825 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 01-23-6 > Nov > 01 > Engine Coolant - Propylene Glycol Recommendations Coolant: All Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 01-23-6 > Nov > 01 > Engine Coolant - Propylene Glycol Recommendations > Page 2831 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement Technical Service Bulletin # 98B33 Date: 990401 Campaign - Coolant/Cylinder Head Replacement OWNER NOTIFICATION PROGRAM 98B33 Certain 1997 and 1998 Expedition, F-150 and 1998 Navigator vehicles equipped with 4.6L and 5.4L engines for inspection of coolant and, if necessary, replacement of engine cylinder heads ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Requirements ^ Attachment IIIA ^ A - Coolant Test Instructions ^ Attachment IIIB ^ B - Cylinder Head Replacement Instructions ^ Attachment IV ^ Copy of Lincoln Commitment Special Handling Procedure Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2836 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2837 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles on the enclosed list. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2838 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with this special handling procedure. CLAIMS Enter claims using DWE. See ACESII Manual. To claim for the "Lincoln Commitment Special Handling", follow the instructions on Attachment IV. OWNER REFUNDS See ACESII Manual, Section 3 for submission procedures. For owner-paid repairs of cracked cylinder heads or damage directly related to cracked cylinder heads made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from servicing dealer), enter using DWE: RENTAL CARS If cylinder head replacement is necessary, Ford will pay for a loaner or rental vehicle except for fuel and insurance which will be at the owner's expense. Do not provide a rental vehicle while cylinder heads are on order. Rentals should be provided only while the vehicle is at the dealership for cylinder head replacement. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days vehicle was used in the Miscellaneous Expense area of the recall claim. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2839 COOLANT TESTER Coolant concentrate test kits will be sent at no charge 10 dealers with affected vehicles. Additional stock of testers is limited, but testers may be ordered from the Recall Hotline 1-800-325-5621. PARTS REQUIREMENTS Parts Ordering Information Cylinder head kits can be ordered by calling the Recall Hotline at 1-800-325-5621. The kits listed contain all parts necessary for cylinder head replacement except coolant, oil and oil filter: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2840 DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 98B33 ^ Labor Operation: (see Labor Allowances) See the ACESII manual for detailed instructions. Attachment IIIA - A-Coolant Test Instructions SERVICE PROCEDURE 1. Open hood. 2. Remove coolant recovery bottle cap. 3. Run engine until normal operating temperature (thermostat open) is reached. 4. Insert supplied glycol tester (Thexton 106) into coolant recovery bottle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2841 5. Fill tester to level shown in Figure 1. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2842 ^ If five (5) or less discs float, refer to Figure 2, no service action is needed. Return vehicle to customer. ^ If all six (6) discs float, indicating "NOT SAFE" glycol condition, see Figure 2, call Recall Hotline at 1-800-325-5621 to order cylinder head kit. Perform cylinder head replacement, when kit arrives. Removal Removal 1. On air suspension equipped vehicles, turn air suspension switch, located in the RH kick panel area, to the OFF position. 2. Install memory saver, then disconnect battery negative cable. 3. Remove shield covering throttle body assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2843 4. Disconnect mass air flow (MAF) sensor electrical connector. Refer to Figure 1. 5. Disconnect intake air temperature (IAT) sensor electrical connector. Refer to Figure 1. 6. Remove air cleaner half and clean air tube as an assembly. See Figure 1. 7. Remove remaining half of air cleaner. 8. Disconnect accelerator cable, speed control cable and return spring from throttle body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2844 9. Remove accelerator cable bracket from intake manifold, then unclip cables from clip on power steering reservoir bracket. See Figure 2. Position cable assembly aside. 10. On 4.6L engines, proceed as follows: ^ Disconnect vapor management valve (VMV) vacuum line at rear of throttle body adapter. Refer to Figure 3. ^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 3. ^ Disconnect PCV hose at rear of throttle body adapter. Refer to Figure 3. ^ Remove brake booster vacuum line retainer at EGR valve. Disconnect vacuum line at throttle body adapter. See Figure 3. Position line aside. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2845 ^ Disconnect vapor management valve (VMV) vacuum line. Refer to Figure 4. ^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 4. ^ Disconnect EGR valve vacuum line. Refer to Figure 4. ^ Disconnect EVR solenoid vacuum line. See Figure 4. ^ Position vacuum harness away from engine. 11. On 5.4L engines, proceed as follows: ^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 5. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2846 ^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle. 12. Raise vehicle. 13. Disconnect EGR tube from exhaust manifold. 14. Disconnect oil pressure switch electrical connector. See Figure 6. 15. Disconnect crankshaft position (CKP) sensor electrical connector. See Figure 7. 16. On 4X2 models, disconnect A/C clutch electrical connector. 17. Drain coolant from radiator. NOTE: Do not remove right side cylinder block coolant drain plug. 18. Remove left side cylinder block coolant drain plug. Allow coolant to completely drain. 19. Install cylinder block coolant drain plug. Tighten plug to 16-24 Nm (12-17 lb-ft). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2847 20. Drain engine oil. Do not final tighten drain plug at this time, as it will be removed again. 21. Lower vehicle. NOTE: The best access to the A/C electrical connector is through the wheel well. 22. On 4X4 models, disconnect A/C clutch electrical connector. 23. Mark and disconnect DPFE transducer hoses from EGR tube. 24. Disconnect EGR tube from EGR valve, then remove EGR tube from vehicle. 25. On 4.6L engines, proceed as follows: ^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 8. ^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2848 ^ Disconnect EVR solenoid electrical connector. Refer to Figure 9. ^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 9. ^ Disconnect Idle Air Control (IAC) motor electrical connector. Refer to Figure 9. ^ Disconnect DPFE transducer electrical connector. See Figure 9. ^ Disconnect left side coil pack electrical connector. Refer to Figure 10. ^ Disconnect camshaft position (CMP) sensor electrical connector. Refer to Figure 10. ^ Disconnect left side radio interference suppressor electrical connector. See Figure 10. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2849 ^ Disconnect ignition wires from left side coil pack. ^ Remove left side coil pack from vehicle. ^ Unclip left side fuel charge harness from cam cover studs. Refer to Figure 11. ^ Unclip ignition wire separators from left cam cover studs. See Figure 11. ^ Disconnect ignition wires from left side spark plugs. Route ignition wires to front of engine. ^ Disconnect left side fuel injector electrical connectors. 26. On 5.4L engines, proceed as follows: ^ Disconnect Vapor Management Valve (VMV) vacuum line. Refer to Figure 12. ^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 12. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2850 ^ Disconnect EGR valve vacuum line. Refer to Figure 12. ^ Disconnect EVR solenoid vacuum line. See Figure 12 ^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 13. ^ Position vacuum harness away from engine. ^ Disconnect VMV purge line at top of throttle body adapter. See Figure 13. ^ Disconnect brake booster vacuum line from throttle body adapter. ^ Remove brake booster vacuum line bracket from intake manifold. Position vacuum line assembly away from intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2851 ^ Disconnect Idle Air Control (IAC) motor electrical connector. See Figure 14. ^ Disconnect left side radio interference suppressor electrical connector. Refer to Figure 15. ^ Disconnect DPFE transducer electrical connector. Refer to Figure 15. ^ Disconnect EVR solenoid electrical connector. Refer to Figure 15. ^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 15. ^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2852 ^ Disconnect camshaft position (CMP) sensor electrical connector. See Figure 16. ^ Disconnect ignition coil electrical connectors from left side of engine. Refer to Figure 17. ^ Disconnect fuel injector electrical connectors from left side of engine. See Figure 17. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2853 ^ Remove left side fuel charge harness from cam cover studs, then position harness away from cam cover. See Figure 18. ^ Remove left side ignition coils from vehicle. WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 27. Relieve fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on EFI/CFI fuel pressure gauge. ^ Remove fuel pressure gauge and reinstall schrader valve cap. 28. Disconnect fuel lines from fuel manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2854 29. Remove junction block splash shield. See Figure 19. 30. Disconnect positive leads from starter relay. Refer to Figure 20. 31. Unclip two (2) mega-fuses from bracket. Refer to Figure 20. 32. Disconnect two (2) 42-pin bulkhead electrical connectors. Refer to Figure 20. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2855 33. Remove both bulkhead electrical connector halves from bracket. See Figure 20. 34. Disconnect 16-pin electrical connector. Refer to Figure 21. 35. Disconnect single-pin electrical connector. Refer to Figure 21. 36. Remove junction block bracket. See Figure 21. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2856 37. Remove heater supply hose from vehicle. Refer to Figure 22. 38. Disconnect heater return hose from heater core fitting. Then position hose away from right cam cover. Refer to Figure 22. 39. Remove ground strap to bulkhead retaining bolt, then unwrap ground strap from fuel manifold. See Figure 22. 40. Remove PCV valve and line from vehicle. 41. On 4.6L engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2857 ^ Disconnect right side coil pack electrical connector. Refer to Figure 23. ^ Disconnect right side radio interference suppressor electrical connector. Refer to Figure 23. ^ Disconnect ignition wires from right side coil pack. See Figure 23. ^ Remove right side coil pack from vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2858 ^ Unclip right side fuel charge harness from cam cover studs. Refer to Figure 24. ^ Unclip ignition wire separators from right cam cover studs. See Figure 24. ^ Disconnect ignition wires from right side spark plugs. Route ignition wires to front of engine. ^ Disconnect right side fuel injector electrical connectors. ^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. Refer to Figure 25. ^ Disconnect water temperature sender electrical connector. Refer to Figure 25. ^ Remove tie strap retaining alternator wiring harness to fuel manifold. See Figure 25. 42. On 5.4L engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2859 ^ Disconnect right side radio interference suppressor. See Figure 26. ^ Disconnect ignition coil electrical connectors from right side of engine. Refer to Figure 27. ^ Disconnect fuel injector electrical connectors from right side of engine. See Figure 27. ^ Remove right side fuel charge harness from cam cover studs, then position harness away from cam cover. ^ Remove right side ignition coils from vehicle. ^ Remove tie strap retaining alternator wiring harness to fuel manifold. 43. Disconnect upper radiator hose from thermostat housing. 44. Remove drive belt. 45. Remove alternator and mounting bracket as an assembly. The ignition wires and the alternator wiring harness will also be removed with the alternator assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2860 46. Disconnect cylinder head temperature (CHT) sensor electrical connector. Refer to Figure 28. 47. Disconnect tuning valve electrical connector. See Figure 28. 48. Remove the intake manifold retaining bolts. See Figure 29. 49. Remove intake manifold from vehicle. 50. Remove and discard intake manifold gaskets. NOTE: On 5.4L engine, cam cover bolts cannot be separated from cam cover. NOTE: Be careful not to damage cam cover gaskets, as they will be reused. Remove both camshaft covers. 51. Remove both camshaft covers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2861 52. Disconnect heater return hose from coolant tube, then remove heater hose from vehicle. Refer to Figure 30. 53. Remove retainers securing routing bracket to rear of right-hand cylinder head, then remove routing bracket and ground strap. Refer to Figure 30. 54. Remove coolant tube retainers securing coolant tube to rear of right hand cylinder head, then remove coolant tube. See Figure 30. 55. Remove jack handle from radiator air deflector. 56. Remove air deflector on top of radiator. 57. Disconnect coolant recovery hose from radiator. 58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, remove cooling fan and clutch assembly. 59. Remove cooling fan shroud. 60. On automatic transmission models, disconnect transmission lines from radiator. 61. Disconnect lower radiator hose from radiator. 62. Remove radiator support brackets, then the radiator. 63. Remove water pump pulley, then the water pump. 64. On 4.6L and 5.4L Windsor engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2862 ^ Remove two (2) upper power steering pump retaining bolts. Refer to Figure 31. ^ Raise vehicle. ^ Remove one (1) lower power steering pump retaining bolt, then position power steering pump away from front engine cover. See Figure 31. 65. On Romeo engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2863 ^ Remove two (2) upper power steering pump retaining bolts. See Figure 32. ^ Raise vehicle. NOTE: One of the following bolts cannot be completely removed from the power steering pump due to clearance with the power steering line. ^ Remove two (2) lower power steering pump retaining bolts, then position power steering pump away from front engine cover. See Figure 33. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2864 66. Remove four (4) front oil pan bolts. See Figure 34. 67. Lower vehicle. 68. Using Crankshaft Damper Remover T58P-6316-D, remove crankshaft pulley. 69. Using Front Cover Seal Remover T74P-6700-A, remove engine front cover oil seal. 70. Remove idler pulley from right side of engine front cover. This pulley blocks a front cover bolt. 71. Remove engine front cover retainers. See Figure 35. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2865 72. Remove engine front cover from engine. See Figure 36. 73. Remove crankshaft sensor ring. 74. Using Crankshaft Holding Tool T93P-6303-A, rotate crankshaft until crankshaft keyway points to the 12 o'clock position. See Figure 37. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2866 75. Install Camshaft Holding Tool T96T-6256-B, on each camshaft. See Figure 38 for holding tool placement. 76. Remove both timing chain tensioners. See Figure 39. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2867 77. Remove both timing chain tensioner guides. See Figure 40. 78. Lift right-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. Refer to Figure 41. 79. Lift left-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. See Figure 41. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2868 80. Remove both timing chain guides. See Figures 42 and 43. NOTE: Removal of this wheel opening molding screw is necessary to access all screws for the fender splash shield. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2869 81. On 4X4 models, remove one (1) screw shown in Figure 44, from both wheel opening moldings. 82. Remove both front fender splash shields. See Figure 45. 83. Raise vehicle. 84. Disconnect exhaust Y-pipe from exhaust manifolds. 85. Slightly lower vehicle. Exhaust manifold retainers will be accessed through the wheel well opening. 86. Remove left side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged. 87. Loosen engine oil indicator tube; then turn tube away from cylinder head. Removal of indicator tube is not necessary. 88. Remove right side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged. 89. Remove retainer securing transmission indicator tube to right cylinder head if equipped. NOTE: Cylinder head bolts that are under the camshaft holding tools cannot be completely removed from the head due to clearance with the holding tool. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2870 Completely loosen these bolts. 90. Remove both cylinder heads. See Figure 46. Discard all cylinder head bolts. 91. Remove and discard both cylinder head gaskets. 92. On Romeo engines, proceed as follows: ^ Remove spark plugs from right cylinder head. ^ Remove camshaft sprocket from right side camshaft. ^ Remove Camshaft Holding Tool from right side camshaft. ^ Install camshaft sprocket on new right side camshaft. Do not final tighten retaining bolt at this time. ^ Remove spark plugs from left cylinder head. ^ Remove camshaft sprocket from left side camshaft. ^ Remove Camshaft Holding Tool from left side camshaft. ^ Install camshaft sprocket on new left side camshaft. Do not final tighten retaining bolt at this time. ^ Remove power steering reservoir bracket and CHT sensor from left cylinder head. 93. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Remove Camshaft Holding Tools from both camshafts. ^ Remove power steering reservoir bracket and Cylinder Head Temperature sensor from left cylinder head. ^ Remove all eight (8) spark plugs from cylinder heads. 94. Clean the following gasket surfaces: ^ Cylinder block to cylinder head. ^ Engine front cover. ^ Water pump. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2871 ^ Intake manifold. ^ Both cam covers. Installation 1. On all cylinder heads, install one (1) pipe plug into the rear of each cylinder head in locations shown in Figure 47. 2. On 4.6L Romeo engines, install one (1) pipe plug into the front of each cylinder head in locations shown in Figure 48. 3. Install CHT sensor to left cylinder head. Tighten sensor to 24-28 Nm (17-20 lb-ft). 4. Install power steering bracket to left cylinder head. 5. Install all spark plugs (both sides). Tighten plugs to 9-20 Nm (81-178 lb-in). 6. Install right cylinder head gasket. 7. Install right cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2872 8. Tighten right cylinder head bolts in sequence shown in Figure 49 in the following three (3) stages: ^ Stage 1: 37-43 Nm (27-32 lb-ft). ^ Stage 2: Rotate 85-95 degrees. ^ Stage 3: Rotate 85-95 degrees. 9. Lubricate all camshaft journals. 10. Install left cylinder head gasket. 11. Install left cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2873 12. Tighten left cylinder head bolts in sequence shown in Figure 50 in the following three (3) stages: ^ Stage 1: 37-43 Nm (27-32 lb-ft). ^ Stage 2: Rotate 85-95 degrees. ^ Stage 3: Rotate 85-95 degrees. 13. Lubricate all camshaft journals. 14. Raise vehicle. 15. Install transmission indicator tube retainer to right cylinder head if equipped. Tighten retainer to 18-23 Nm (14-16 lb-ft). 16. Install right side exhaust manifold gasket. NOTE: Due to clearance, the exhaust system Y-pipe mounting flange cannot be positioned on the exhaust manifold outlet after the exhaust manifold is installed on the cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2874 17. Install right side exhaust manifold and gasket. Align exhaust system Y-pipe mounting flange with the studs in the exhaust manifold outlet before completely installing the exhaust manifold on the cylinder block. Tighten right side exhaust manifold retainers in sequence shown in Figure 51 to 18-22 Nm (13-16 lb-ft). 18. Position engine oil indicator tube in installed position. 19. Install left side exhaust manifold and gasket. Tighten retainers in sequence shown in Figure 52 to 18-22 Nm (13-16 lb-ft). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2875 20. Remove oil pan drain plug. Completely drain any fluid (oil, coolant) from oil pan. Reinstall drain plug, tightening to 11-16 Nm (98-143 lb-in). 21. Replace oil filter. 22. Install exhaust system Y-pipe to exhaust manifolds. Tighten retainers to 34-46 Nm (25-34 lb-ft). 23. Lower vehicle. 24. Install both fender splash shields. Tighten retainers to 10-13 Nm (89-115 lb-in). 25. On 4X4 models, install one screw removed from both wheel opening moldings. 26. On Romeo engines, proceed as follows: ^ Using socket on camshaft sprocket bolt, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53. ^ Using socket on camshaft sprocket bolt, rotate right camshaft until timing mark is in 11 o'clock position. Refer to Figure 53. 27. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Using Camshaft Positioning Tool T96T-6256-AR, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53. ^ Using Camshaft Positioning Tool T96T-6256-AR, rotate right camshaft until timing mark is in 11 o'clock position. See Figure 53. ^ Install Camshaft Holding Tool T96T-6256-B on each camshaft. 28. On Romeo engines, tighten both camshaft sprocket bolts to 110-130 Nm (81-95 lb-ft). CAUTION Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and/or valve damage can occur. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2876 29. Rotate crankshaft using Crankshaft Holding Tool T93P-6303-A. See Figure 54. Fully install holding tool. This will position crankshaft keyway to about 10:30 position. 30. Remove Crankshaft Holding Tool. 31. Compress timing chain tensioner plunger as follows: CAUTION Do not compress the ratchet assembly. This will damage the ratchet assembly. CAUTION Use protective vocers over jaws of vise to prevent damage to tensioner. ^ Compress tensioner plunger using edge of vise. See Figure 55. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2877 ^ Using small screwdriver or pick, push back and hold ratchet mechanism. See Figure 56. ^ While holding ratchet mechanism, push ratchet arm back into tensioner housing. See Figure 57. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2878 ^ Install paper clip into hole in tensioner housing. This will hold ratchet assembly and plunger in during installation. See Figure 58. ^ Remove tensioner from vise. ^ Repeat procedure for second tensioner. 32. If copper links are not visible, mark one (1) link on each end of the timing chain. One link will be an inside link. Use these marks as timing marks. See Figure 59. Repeal this step for other timing chain, if necessary. 33. Install right side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in). 34. Install left side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in). 35. Install timing chains and sprockets as follows: ^ Position left side crankshaft sprocket in left side timing chain. Make sure crankshaft sprocket hub is facing outward. Align mark on timing chain with corresponding dot on crankshaft sprocket. ^ Slide left side sprocket and chain on crankshaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2879 ^ Position left side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned. ^ Position right side crankshaft sprocket in right side timing chain. Make sure crankshaft sprocket hub is facing inward. Align mark on timing chain with corresponding dot on crankshaft sprocket. ^ Slide right side sprocket and chain on crankshaft. ^ Position right side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned. ^ Make sure marks on timing chain are lined up with corresponding dots on crankshaft and camshaft sprockets. See Figure 60. ^ Make sure right side crankshaft sprocket is in front of left side crankshaft sprocket with hubs facing each other. See Figure 61. 36. Install right and left timing chain tensioner guides. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2880 37. Install right and left timing chain tensioners. Tighten retainers to 20-30 Nm (15-20 lb-ft). 38. Remove paper clips from both timing chain tensioners. 39. Remove both camshaft holding tools. 40. Install crankshaft sensor ring. 41. Install engine front cover as follows: NOTE: The engine front cover must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, along head to block surface and oil pan to block surface. See Figure 62. ^ Using new gasket, install engine front cover. Align cover with cylinder block dowel. ^ Loosely install engine front cover bolts and stud bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2881 ^ Tighten first five (5) engine front cover bolts in sequence shown in Figure 63, to 20-30 Nm (15-22 lb-ft). ^ Tighten remaining ten (10) engine front cover bolts in sequence shown in Figure 64. On Romeo engines, tighten bolts to 20-30 Nm (15-22 lb-ft). On 4.6L and 5.4L Windsor engines, tighten bolts to 40-55 Nm (29-40 lb-ft). 42. Install right side idler pulley. Tighten retainer to 20-30 Nm (15-22 lb-ft). 43. Using clean engine oil, lubricate engine front cover oil seal inner lip. 44. Using Crankshaft Seal Replacer/Aligner T88T-6701-A, install front cover oil seal. 45. Install crankshaft pulley as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2882 NOTE: The crankshaft pulley must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to woodruff key slot on crankshaft pulley. See Figure 65. ^ Using Crankshaft Damper Replacer T74P-6316-B, install crankshaft pulley. ^ Loosely install crankshaft pulley bolt. ^ Tighten crankshaft pulley bolt to 90 Nm (66 lb-ft). ^ Loosen crankshaft pulley bolt one (1) full turn. ^ Tighten crankshaft pulley bolt to 47-53 Nm (34-39 lb-ft). ^ Tighten crankshaft pulley bolt an additional 85-90 degrees (1/4 turn). 46. On Romeo engines, proceed as follows: ^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft). ^ Raise vehicle. ^ Install two (2) power steering pump lower retaining bolts. Tighten bolt to 20-30 Nm (15-22 lb-ft). 47. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft). ^ Raise vehicle. ^ Install power steering pump lower retaining bolt. Tighten bolt to 20-30 Nm (15-22 lb-ft). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2883 48. Loosely install four (4) front oil pan bolts. Tighten bolts in sequence shown in Figure 66, in the following two (2) stages: ^ Stage 1: 20 Nm (15 lb-ft). ^ Stage 2: Rotate an additional 60 degrees. 49. Lower vehicle. 50. Using coolant, lubricate new water pump O-ring seal. Install seal on water pump. 51. Install water pump. Tighten retainers in sequence shown in Figure 67, to 20-30 Nm (15-22 lb-ft). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2884 52. Install water pump pulley. Tighten retainers in sequence shown in Figure 68, to 20-30 Nm (15-22 lb-ft). 53. Install radiator. Make sure radiator is sitting on mounting insulators. 54. Install radiator supports. Tighten retainers to 25-35 Nm (18-26 lb-ft). 55. Connect lower radiator hose to radiator. 56. On automatic transmission models, connect transmission cooler lines to radiator. Tighten lines to 16-24 Nm (12-18 lb-ft). 57. Install cooling fan shroud. Tighten retainer 108-10 Nm (71-89 lb-in). 58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, install cooling fan and clutch assembly. 59. Connect coolant recovery hose to radiator. 60. Install air deflector on top of radiator. 61. Install jack handle on radiator air deflector. 62. Using clean coolant, lubricate coolant tube O-ring seal. Install coolant tube. Tighten retainers on rear of right cylinder head to 40-55 Nm (29-40 lb-ft). NOTE: Make sure left side fuel charge harness is between routing bracket and cylinder head. 63. Install routing bracket and ground strap to rear of right cylinder head. Tighten retainers to 9-12 Nm (80-107 lb-in). 64. Install heater return hose to coolant tube. 65. Install cam cover gaskets on both cam covers. NOTE: The cam cover must be installed within four (4) minutes after applying silicone. 66. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2885 67. Install right side cam cover. Tighten retainers in sequences shown in Figures 69 and 70, to 8-12 Nm (71-107 lb-in). NOTE: The cam cover must be installed within four (4) minutes after applying silicone. 68. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2886 69. Install left side cam cover. Tighten retainers in sequences shown in Figures 71 and 72, to 8-12 Nm (71-107 lb-in). 70. Install new intake manifold gaskets. 71. Install intake manifold (including thermostat housing). Tighten bolts in sequence shown in Figure 73, in the following two (2) stages: ^ Stage 1: 2 Nm (18 lb-in). ^ Stage 2: 20-30 Nm (15-22 lb-ft). 72. Loosely position left side fuel charge harness on cam cover. 73. Connect tuning valve electrical connector. 74. Connect CHT sensor electrical connector. 75. Install alternator assembly. Tighten front alternator bolts to 21-28 Nm (15-21 lb-ft). Tighten alternator bracket bolts to 9-12 Nm (80-106 lb-in). 76. Install drive belt. 77. Using tie strap, retain alternator wiring harness to fuel manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2887 78. On 4.6L engines, proceed as follows: ^ Loosely position right side fuel charge harness on cam cover. ^ Connect water temperature sensor electrical connector. ^ Connect ECT sensor electrical connector. ^ Connect right side ignition wires to spark plugs. ^ Clip ignition wire separators to right cam cover. ^ Connect right side fuel injector electrical connectors. ^ Clip right side fuel charge harness to cam cover. ^ Install right side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft). ^ Connect ignition wires to right side coil. ^ Connect right side radio interference suppressor electrical connector. ^ Connect right side coil pack electrical connector. 79. On 5.4L engines, proceed as follows: ^ Install right side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in). ^ Position right side fuel charge harness on cam cover studs. ^ Connect right side fuel injector electrical connectors. ^ Connect right side ignition coil electrical connectors. ^ Connect right side radio interference suppressor. 80. Install PCV valve and line assembly. 81. Connect ground strap to bulkhead. 82. Connect heater return hose to heater core. 83. Install heater supply hose. 84. Install junction block bracket. Tighten retainers securely. 85. Connect single-pin electrical connector. 86. Connect 16-pin electrical connector. 87. Install both 42-pin bulkhead electrical connector halves to junction block bracket. 88. Connect both 42-pin bulkhead electrical connectors. Tighten retainers to 4-5 Nm (35-44 lb-in). 89. Clip two (2) mega-fuses to junction block bracket. 90. Connect positive leads to starter relay. 91. Install junction block bracket splash shield. 92. Connect fuel lines to fuel manifold. 93. On 4.6L engines, proceed as follows: ^ Connect left side ignition wires to spark plugs. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2888 ^ Clip ignition wire separators to left cam cover. ^ Connect left side fuel injector electrical connectors. ^ Clip left side fuel charge harness to cam cover. ^ Install left side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft). ^ Connect ignition wires to left side coil. ^ Connect left side radio interference suppressor electrical connector. ^ Connect CMP electrical connector. ^ Connect left side coil pack electrical connector. ^ Connect DPFE transducer electrical connector. ^ Connect IAC motor electrical connector. ^ Connect TP sensor electrical connector. ^ Connect EVR solenoid electrical connector. ^ Connect crankcase vent tube to left cam cover. ^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft). 94. On 5.4L engines, proceed as follows: ^ Install left side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in). ^ Connect left side fuel injector electrical connectors. ^ Connect left side ignition coil electrical connectors. ^ Connect ECT sensor electrical connector. ^ Connect TP sensor electrical connector. ^ Connect EVR solenoid electrical connector. ^ Connect DPFE transducer electrical connector. ^ Connect left side radio interference suppressor electrical connector. ^ Connect IAC motor electrical connector. ^ Connect brake booster vacuum line to throttle body adapter, then install brake booster vacuum line bracket to intake manifold. ^ Connect VMV purge line to top of throttle body adapter. ^ Position vacuum harness on top of motor. ^ Connect vacuum tap to right side of throttle body adapter. ^ Connect EVR solenoid vacuum line. ^ Connect EGR valve vacuum line. ^ Connect fuel pressure regulator vacuum line. ^ Connect vapor management valve vacuum line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2889 95. Connect EGR tube to EGR valve. Hand-tighten fitting at this time. 96. Connect DPFE transducer hoses to EGR tube. 97. On 4X4 models, connect A/C clutch electrical connector. 98. Raise vehicle. 99. Connect EGR tube to exhaust manifold. Tighten fitting to 35-45 Nm (26-33 lb-ft). 100. On 4X2 models, connect A/C clutch electrical connector. 101. Connect CKP sensor electrical connector. 102. Connect oil pressure switch electrical connector. 103. Lower vehicle. 104. Final tighten EGR tube to valve to 35-45 Nm (26-33 lb-ft). 105. On 4.6L engines, proceed as follows: ^ Loosely position vacuum harness over engine. ^ Connect EVR solenoid vacuum line. ^ Connect EGR valve vacuum line. ^ Connect fuel pressure regulator vacuum line. ^ Connect vapor management valve vacuum line. ^ Position brake booster vacuum line in installed position. Connect line to tap on throttle body adapter. Tighten line retainer at EGR valve to 8-12 Nm (71-106 lb-in). ^ Connect vacuum tap on right side of throttle body adapter. ^ Connect VMV vacuum line at rear of throttle body adapter. 106. On 5.4L engines, proceed as follows: ^ Connect crankcase vent tube to left cam cover. ^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft). 107. Position accelerator/speed control cables on top of engine. Secure cables to clip on power steering reservoir. 108. Install accelerator cable bracket to intake manifold. Tighten retainer to 6-8 Nm (53-71 lb-in). 109. Connect accelerator cable, speed control cable and return spring to throttle body. 110. Connect upper radiator hose to thermostat housing. 111. Install rear half of air cleaner. 112. Install front half of air cleaner and clean air lube. 113. Connect IAT and MAF electrical connectors. 114. Install throttle body shield. 115. Connect battery negative cable. 116. Remove memory saver. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2890 117. Fill engine with new engine oil. 118. Fill cooling system as follows: ^ Add 50/50 coolant mixture to radiator coolant recovery reservoir. ^ Install radiator cap. ^ Move temperature blend selector to full warm position. ^ Run engine until it reaches operating temperature. ^ Add 50/50 coolant mixture to radiator coolant recovery reservoir until the coolant level is between the "COOLANT FILL LEVEL" marks. ^ Turn off engine and allow cooling system to cool. ^ Repeat bulleted steps until radiator coolant recovery reservoir level remains in between fill level marks when engine is cool. 119. On air suspension equipped models, turn air suspension switch to ON position. 120. Check engine for proper operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2891 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2892 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2893 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2894 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 2895 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 01-23-6 > Nov > 01 > Engine Coolant - Propylene Glycol Recommendations Coolant: All Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 01-23-6 > Nov > 01 > Engine Coolant - Propylene Glycol Recommendations > Page 2901 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity With 1-row radiator 18 qts .............................................................................................................................................................. ................................. With 2-row radiator 19.9 qts .............................................................................................................................................................. ................................. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2904 Coolant: Fluid Type Specifications COOLANT TYPE Ethylene Glycol (EC) .............................................................................................................................................................. ........... Coolant Mixture with Water 50% .............................................................................................................................................................. ........................ Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the correct coolant type. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications TORQUE SPECIFICATIONS Cylinder Block Drain Plug ......................................................................................................................................................... 16-24 Nm (11-18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications Coolant Reservoir: Specifications TORQUE SPECIFICATIONS Coolant Recovery Reservoir Bolts ............................................................................................................................................ 8-10 Nm (71-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 2911 Coolant Reservoir: Service and Repair REMOVAL 1. Partially drain the cooling system. 2. Remove the hose from the radiator. 1 Release the hose clamp and slide away from the hose end. 2 Slide the hose off the radiator fitting. 3. Remove the lower radiator hose from the degas bottle. 4. Remove the degas bottle. 1 Remove the bolts. 2 Remove the degas bottle. INSTALLATION Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Engine View The Cooling Fan Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Description and Operation Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications Fan Blade: Specifications TORQUE SPECIFICATIONS Fan Assembly To Fan Clutch Bolts ............................................................................................................................................ 15-20 Nm (11-15 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 2922 Fan Blade: Service and Repair REMOVAL WARNING: DO NOT RUN THE ENGINE WHILE THE PROTECTIVE COMPONENTS ARE REMOVED. NOTE: The fan, fan clutch and shroud must be removed as an assembly. 1. Remove the Engine Air Cleaner (ACL). 2. Drain the engine cooling system. 3. Remove the front air deflector. 1 Remove the screws. 2 Remove the front air deflector. 4. Remove the upper radiator hose from the radiator. 5. Remove the coolant recovery reservoir hose from the radiator. 1 Release the (A) hose clamp and slide it away from the end of the (B) hose. 2 Slide the (A) coolant recovery reservoir hose off the (B) radiator fitting. 6. Remove the fan blade and fan clutch. 1 Use Fan Clutch Holding Tool to hold the water pump pulley steady. 2 Use Fan Clutch Wrench to remove the fan blade and the fan clutch. NOTE: The fan clutch has LH threads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 2923 7. Remove the fan shroud. 1 Remove the screws. 2 Lift and remove the fan shroud and fan blade out of the vehicle together. 8. Remove the fan and shroud out of the vehicle together. 9. Separate the fan clutch from the fan blade. 1 Remove the bolts. 2 Separate the (A) fan blade from the (B) fan clutch. INSTALLATION 1. Assemble the fan clutch to the fan blade. 1 Position the (A) fan clutch on the (B) fan blade 2 Install the bolts. 2. Position the fan shroud and the fan blade. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 2924 3. Install the fan shroud. 1 Lower the fan shroud onto the radiator clips. 2 Install the screws. 4. Install the fan blade and the fan clutch. 1 Position the fan blade assembly and the fan clutch on the water pump pulley. 2 Use Fan Clutch Holding Tool to hold the water pump pulley steady. 3 Use Fan Clutch Wrench to install the fan blade and fan clutch. NOTE: The fan clutch has LH threads. 5. Connect the degas bottle hose to the radiator. 1 Push the (A) degas bottle hose onto the (B) radiator fitting. 2 Position and tighten the hose clamp. 6. Connect the upper radiator hose to the radiator. 7. Install the front air deflector. 1 Position the front air deflector. 2 Install the screws. 8. Fill the engine cooling system. 9. Install the engine air cleaner. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 2925 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications Fan Clutch: Specifications TORQUE SPECIFICATIONS Fan Clutch To Water Pump Pulley ............................................................................................................................................ 47-63 Nm (35-46 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 2929 Fan Clutch: Testing and Inspection 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 water 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 the Digital Photoelectric Tachometer. 5. Start the engine and run it at approximately 1500 rpm until the normal operating temperature has been achieved. 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. 6. Adjust the engine speed to 2300 rpm. 7. Operate the strobe light at 3000 rpm and aim it at the water pump pulley. Adjust the engine speed until the light flash and the water pump pulley mark are synchronized. 8. Aim the strobe light 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 1500 rpm at 3000 water pump rpm. 10. Turn the engine off. 11. If the fan blade speed was greater than 1500 rpm, replace the fan clutch. Fan Clutch Test-Maximum Speed Requirement 1. Perform Steps 1 through 5 of the Fan Clutch Test-Minimum Speed Requirement. 2. 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. NOTE: The temperature should be above 96°C (205°F) for maximum fan speed. 3. Place the climate control function selector switch in the MAX A/C position and the blower motor switch in the HI position. 4. Adjust the strobe to 3000 rpm. 5. Start the engine and adjust the engine speed until the strobe light flash and the water pump pulley mark are synchronized. 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. 6. Aim the strobe light at the fan blade retaining bolts. Adjust the strobe 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 2300 rpm, replace the fan clutch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 2930 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor ............................................................................................................................... 16-24 Nm (11.8-17.4 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2935 Engine Views Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2936 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Remove the Engine Coolant Temperature sensor (ECT sensor). 1 Disconnect the electrical connector. 2 Remove the engine coolant temperature sensor. INSTALLATION 1. Install the engine coolant temperature sensor. 1 Install the engine coolant temperature sensor. 2 Connect the electrical connector. 2. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Description and Operation Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications Cylinder Head Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor ...................................................................................................................................... 19-25 Nm (14-18 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications > Page 2943 Cylinder Head Temperature Sensor: Locations Engine View The Cylinder Head Temperature Sensor is located on the top front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications > Page 2944 Cylinder Head Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the cylinder head temperature sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. Install the CHT sensor. 1 Install the sensor. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Service and Repair Temperature Sensor (Gauge): Service and Repair REMOVAL 1. Partially drain the engine cooling system. 2. Remove the water temperature indicator sender unit. 1 Disconnect the electrical connector. 2 Remove the water temperature indicator sender unit. INSTALLATION 1. Install the water temperature indicator sender unit. 1 Install the water temperature indicator sender unit. 2 Connect the electrical connector. 2. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications Fan Shroud: Specifications TORQUE SPECIFICATIONS Fan Shroud Screws ............................................................................................................................. ...................................... 8-10 Nm (71-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2959 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2960 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 (V8-281 4.6L SOHC (1998)) 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 (V8-281 4.6L SOHC (1998)) 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 2966 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 (V8-281 4.6L SOHC (1998)) 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 2967 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 97-19-11 > Sep > 97 > Heater Core - On Car Pressure Test For Warranty Claim Heater Core: All Technical Service Bulletins Heater Core - On Car Pressure Test For Warranty Claim Article No. 97-19-11 09/15/97 COOLING SYSTEM - "ON-VEHICLE" HEATER CORE PRESSURE TEST REQUIRED FOR WARRANTY CLAIM FORD: 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1993-98 ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: An "On-Vehicle" heater core pressure test is required before replacing any heater core within the warranty period. ACTION: Perform the "On-Vehicle" heater core pressure test by referring to the following heater core leak test procedure. HEATER CORE LEAK TEST PROCEDURE Use the heater core pressure test to determine if the heater core is leaking. Symptoms associated with a leaking heater core include: ^ Engine coolant leaking into the passenger compartment ^ Engine coolant blown onto the windshield during defrost operation ^ Engine coolant odor inside the passenger compartment 1. Partially drain cooling system. 2. Disconnect both heater core hoses. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 97-19-11 > Sep > 97 > Heater Core - On Car Pressure Test For Warranty Claim > Page 2972 3. Attach two (2) pieces of heater hose to the heater core inlet and outlet tubes and clamp (Figure 1). 4. Install Plug (part of 014-R1072) into one (1) heater hose and clamp (Figure 1). 5. Fill heater core and hoses with water. 6. Install Adapter (part of 0144-R1072) into other heater hose and clamp (Figure 1). 7. Attach Radiator/Heater Core Pressure Tester (014-R1072) to Adapter (part of 014-R1072) (Figure 1). 8. Close the bleed valve and the tester and pump air into the heater core until 241 kPa (35 psi) is reached on the tester gauge. 9. Observe the gauge after 3 minutes. The pressure should not drop. If the pressure does drop, there is a leak. Check the hose connections and retest if you find a leak. 10. Replace heater core if pressure drops and hose connections do not leak. 11. Do not replace heater core if pressure does not drop. Pressure test engine cooling system for leaks elsewhere. 12. Reconnect heater core and refill cooling system after all necessary repairs. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208999, 290000, 402000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 97-19-11 > Sep > 97 > Heater Core - On Car Pressure Test For Warranty Claim Heater Core: All Technical Service Bulletins Heater Core - On Car Pressure Test For Warranty Claim Article No. 97-19-11 09/15/97 COOLING SYSTEM - "ON-VEHICLE" HEATER CORE PRESSURE TEST REQUIRED FOR WARRANTY CLAIM FORD: 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1993-98 ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: An "On-Vehicle" heater core pressure test is required before replacing any heater core within the warranty period. ACTION: Perform the "On-Vehicle" heater core pressure test by referring to the following heater core leak test procedure. HEATER CORE LEAK TEST PROCEDURE Use the heater core pressure test to determine if the heater core is leaking. Symptoms associated with a leaking heater core include: ^ Engine coolant leaking into the passenger compartment ^ Engine coolant blown onto the windshield during defrost operation ^ Engine coolant odor inside the passenger compartment 1. Partially drain cooling system. 2. Disconnect both heater core hoses. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 97-19-11 > Sep > 97 > Heater Core - On Car Pressure Test For Warranty Claim > Page 2978 3. Attach two (2) pieces of heater hose to the heater core inlet and outlet tubes and clamp (Figure 1). 4. Install Plug (part of 014-R1072) into one (1) heater hose and clamp (Figure 1). 5. Fill heater core and hoses with water. 6. Install Adapter (part of 0144-R1072) into other heater hose and clamp (Figure 1). 7. Attach Radiator/Heater Core Pressure Tester (014-R1072) to Adapter (part of 014-R1072) (Figure 1). 8. Close the bleed valve and the tester and pump air into the heater core until 241 kPa (35 psi) is reached on the tester gauge. 9. Observe the gauge after 3 minutes. The pressure should not drop. If the pressure does drop, there is a leak. Check the hose connections and retest if you find a leak. 10. Replace heater core if pressure drops and hose connections do not leak. 11. Do not replace heater core if pressure does not drop. Pressure test engine cooling system for leaks elsewhere. 12. Reconnect heater core and refill cooling system after all necessary repairs. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208999, 290000, 402000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2979 Heater Core: Specifications Heater Core Bracket Screws .......................................................................................................................................................... 1.5-2.5 Nm (13-22 Lb-In) Heater Core Outlet Bracket Screws ................................................................................................................................................ 1.5-2.5 Nm (13-22 Lb-In) Evaporator/Heater Core Access Cover Bolts ....................................................................................................................................... 2-3 Nm (18-26 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Auxiliary Heater Core: Description and Operation Auxiliary The auxiliary A/C system uses a rear heater core which operates in the same manner as the front heater core. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Auxiliary > Page 2982 Heater Core: Description and Operation Front 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 2983 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require replacement. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. Perform a system inspection by checking the heater system thoroughly. 2. Check the integrity of the heater water hose clamps. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Heater Core-Plugged WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the proper level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot: the heater core may have an air pocket - the heater core may be plugged, or - the thermostat is not working properly. Heater Core-Pressure Test Use the radiator/heater core pressure tester to perform the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the radiator/heater core pressure tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and perform the bench test. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 2984 Heater Core-Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, replace the heater core. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core Heater Core: Service and Repair Back Flushing-Heater Core 1. Once pressure is released, remove the pressure relief cap. WARNING: NEVER REMOVE THE PRESSURE RELIEF CAP WHILE THE ENGINE IS OPERATING OR WHEN THE COOLING SYSTEM IS HOT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE OR PERSONAL INJURY. TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE DEGAS BOTTLE WHEN REMOVING THE PRESSURE RELIEF CAP, WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE PRESSURE RELIEF CAP AND TURN IT SLOWLY. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN RELEASED, (STILL WITH A CLOTH) TURN AND REMOVE THE PRESSURE RELIEF CAP. 2. Partially drain the cooling system. 3. Use cooling system Flush-All, Flush Kit Hardware Package and Drain Kit to backflush the hater core. Use Ford Premium Cooling System Flush F1AZ-19A503-A meeting Ford specification ESR-M14P7A. 4. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 2987 Heater Core: Service and Repair Removal and Installation Front REMOVAL 1. Disconnect the battery ground cable. 2. Drain the radiator. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Service and Repair 3. Remove the instrument panel. Refer to: "Body and Frame : Interior Trim : Dash Board : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 4. Compress the holding tabs and disconnect the heater water hoses at the heater core. 5. Remove the A/C plenum demister adapter. 1 Remove the screw. 2 Remove the A/C plenum demister adapter. 6. Disconnect the vacuum line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 2988 7. Remove the heater core bracket. 1 Remove the two screws. 2 Remove the bracket. 8. Remove the plenum chamber top. 1 Remove the 13 screws. 2 Remove the plenum chamber top. 9. Remove the blend door assembly from the case. 10. Remove the heater core. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 2989 1. Follow the removal procedure in reverse order. Auxiliary REMOVAL 1. Remove the air conditioning and heater assembly. Refer to: "Heater Core Case : Service and Repair" See: Heating and Air Conditioning/Heater Core Case/Service and Repair 2. Remove the evaporator/heater core access cover. 1 Remove the ten bolts. 2 Remove the evaporator/heater core access cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 2990 3. Remove the heater core. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Page 2991 Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 (V8-281 4.6L SOHC (1998)) 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 3000 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 (V8-281 4.6L SOHC (1998)) 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 3001 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 (V8-281 4.6L SOHC (1998)) 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 (V8-281 4.6L SOHC (1998)) 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 3007 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 (V8-281 4.6L SOHC (1998)) 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 3008 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3009 Heater Hose: Specifications Hose Clamp ......................................................................................................................................... ........................................... 1.6-2.2 Nm (17-22 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line Heater Hose: Service and Repair Front Auxiliary Heater Outlet and Inlet Line REMOVAL NOTE: The front auxiliary heater outlet line is shown; the front auxiliary heater inlet line is similar. 1. Drain the cooling system. 2. Turn the air suspension switch off, if equipped. 3. Raise and support the vehicle. 4. Remove the RH front fender splash shield. 1 Remove the bolts. 2 Remove the pushpins. 3 Remove the front fender splash shield. 5. Remove the four line brackets. 1 Remove the nuts. 2 Remove the bracket by inserting a screwdriver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 6. Disconnect the heater outlet line from the outlet hose coupling. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3012 7. Disconnect the front auxiliary heater outlet line from the rear auxiliary heater outlet line. 1 Remove the nut. 2 Disconnect the line. 8. Cut the heater outlet line in the locations shown. 9. Remove and discard the cut sections. INSTALLATION 1. Install the heater outlet line. - Install the end with the blue tape over the frame. 2. Install the heater outlet line. - Install the end with the red tape over the frame. - Install the end with the yellow tape between the frame and the body vertical flange. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3013 3. Connect the two heater water outlet lines. 1 Connect the fitting. 2 Loosely install the nut. 4. Install the heater water outlet line. - Install the line through the wheel opening. 5. Connect the two heater water outlet lines. 1 Connect the fitting. 2 Loosely install the nut. 6. Tighten the two peanut fittings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3014 7. Install the line brackets. 1 Position the bracket. 2 Install the nut. - Snap the line into the bracket. CAUTION: Verify that clearance exists between the frame and the lines to prevent component damage. NOTE: The bracket must be positioned equally between the white location marks on the line. 8. Connect the heater water outlet line to the engine heater outlet hose coupling. 9. Install the bolts, the pushpins and the front fender splash shield. 10. Lower the vehicle. 11. Turn on the air suspension switch, if equipped. 12. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3015 Heater Hose: Service and Repair Heater Hose Couplings Heater Hose Disconnect Tool SPECIAL TOOL(S) DISCONNECT 1. Depressurize the engine cooling system. WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. Push the Heater Hose Disconnect Tool over the coupling retainer windows to compress the retainer locking tabs. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Tool must be perpendicular to and on the highest point of the coupling. 4. Pull the heater water hose away from the heater core tube. NOTE: A slight twisting motion while pulling on the heater waster hose may be necessary to assist in the removal. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3016 7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer. CONNECT 1. Clean the tubes and lubricate with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESR-M99B112-A. 2. Install a new coupling retainer, spacer, and lubricated O-rings into the quick disconnect coupling housing. 3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the coupling is fully engaged by lightly pulling on the heater water hose. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3017 Heater Hose: Service and Repair Rear Auxiliary Heater Inlet Line REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater inlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3018 9. Remove the four line brackets. 1 Remove the nuts. 2 Remove the bracket by inserting a screwdriver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 10. Cut the line in the positions shown. 11. Remove and discard the cut sections. INSTALLATION 1. Install the heater inlet line. - Install the end with the green tape over the axle between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3019 2. Connect the heater inlet line to the front auxiliary line. 1 Connect the inlet line. 2 Loosely install the nut. 3. Install the heater inlet line. - Install the end with the blue tape between the frame crossmember and the floor pan. 4. Connect the two heater inlet lines. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater inlet line. - Install the end with the red tape between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3020 6. Connect the two heater inlet lines. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater inlet line. - Install the end with the green tape through the floor opening. 8. Connect the two heater inlet lines. 1 Connect the fittings. 2 Loosely install the nut. 9. Tighten the four peanut fittings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3021 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. - Snap the line into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the line. 11. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3022 15. Connect the heater inlet hose coupling. 16. Install the quarter trim access panel. 17. Install the spare tire. 18. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3023 Heater Hose: Service and Repair Rear Auxiliary Heater Outlet Line REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater outlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3024 9. Remove the four line brackets. 1 Remove the nuts. 2 Remove the bracket by inserting a screwdriver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 10. Cut the line in the positions shown. 11. Remove and discard the cut sections. INSTALLATION 1. Install the heater outlet line. - Install the end with the blue tape over the axle between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3025 2. Connect the heater outlet line to the front auxiliary line. 1 Connect the fittings. 2 Loosely install the nut. 3. Install the heater outlet line. - Install the end with the red tape between the frame and the crossmember. 4. Connect the two heater outlet lines. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater outlet line. - Install the end with blue tape between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3026 6. Connect the heater outlet line to the heater outlet line. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater outlet line. - Install the end with the hose through the floor opening. 8. Tighten the four peanut fittings. 9. Install the line brackets. 1 Position the bracket. 2 Install the nut. - Snap the line into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3027 10. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 11. Lower the vehicle. 12. Turn on the air suspension switch, if equipped. 13. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 14. Connect the heater outlet hose coupling. 15. Install the quarter trim access panel. 16. Install the spare tire. 17. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3028 Heater Hose: Service and Repair Removal and Installation REMOVAL 1. Drain the radiator. 2. Disconnect the heater outlet hose at the engine. 3. Disconnect the heater inlet hose at the engine. 1 Loosen the hose clamp. 2 Disconnect the heater inlet hose. 4. Compress the holding tabs and disconnect the heater water hoses at the heater core. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 3029 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Page 3030 Heater Hose Disconnect Tool Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Radiator: Customer Interest A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3043 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3044 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3045 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Radiator: All Technical Service Bulletins A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3051 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3052 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3053 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 3064 Radiator: Specifications TORQUE SPECIFICATIONS Radiator Support Bracket Bolts ................................................................................................................................................. 25-35 Nm (18-26 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 3065 Radiator: Testing and Inspection 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 clearing tank and they will damage aluminum radiators. NOTE: ^ Always install plugs in the oil cooler fittings before leak-testing or cleaning any radiator. ^ Clean the radiator before leak-testing to avoid contamination of tank. 1. Leak-test the radiator in clean water with 138 kPa (20 psi) air pressure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 3066 Radiator: Service and Repair REMOVAL 1. Drain the engine cooling system. 2. Remove the fan blade. 3. Disconnect the transmission fluid cooler fittings. 1 Disconnect the upper transmission fluid cooler fitting. 2 Disconnect the lower transmission fluid cooler fitting. 4. Disconnect the lower radiator hose from the radiator. 1 Pry the locking tab up and out of the slot. 2 Rotate the lower radiator hose. 3 Disconnect the lower radiator hose. 5. Remove the radiator. 1 Remove the bolts. 2 Remove the brackets and the jack handle and wheel nut wrench retainers. 3 Lift the radiator off the radiator mounting insulators. 4 Remove the radiator mounting insulators. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 3067 1. Install the radiator. 1 Install the radiator mounting insulators. 2 Position the radiator on the radiator mounting insulators. 3 Position the brackets and the jack handle and wheel nut wrench retainers. 4 Install the bolts. 2. Connect the lower radiator hose and upper radiator hose. 1 Push the hose onto quick connect fitting. 2 Bend the locking tab into retaining slot. 3. Connect the transmission fluid cooler lines. 1 Connect the lower transmission fluid cooler line. 2 Connect the upper transmission fluid cooler line. 4. Install the fan blade. 5. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications Pressure Relief Cap Opening Pressure ..................................................................................................................................................... 110 kPa (16 psi) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications > Page 3071 Radiator Cap: Testing and Inspection WARNING: NEVER REMOVE THE PRESSURE RELIEF CAP UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE COOLING SYSTEM, USE EXTREME CARE WHEN REMOVING THE PRESSURE RELIEF CAP FROM A HOT DEGAS BOTTLE. WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE PRESSURE RELIEF CAP AND TURN IT SLOWLY ONE TURN (COUNTERCLOCKWISE). STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN CERTAIN ALL THE PRESSURE HAS BEEN RELEASED, REMOVE PRESSURE RELIEF CAP (STILL WITH A CLOTH). 1. Remove the pressure relief cap from the degas bottle. 2. Immerse the pressure relief cap in water and install it on the shallow filler neck of Radiator/Heater Core Pressure Tester and Radiator Cap Adapter, part of Radiator/Heater Core Pressure Tester. 3. Immerse the filler neck seal in water and install it in the filler neck adapter. 4. Install the filler neck adapter with the filler neck seal to the Radiator Cap Adapter. 5. Connect the female quick-connect fitting of the pressure test pump to the male quick-connect fitting of the filler neck adapter. 6. Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops increasing and note the highest pressure reading obtained. NOTE: If the plunger of the pump is depressed too fast, an erroneous pressure reading will result. 7. Release the pressure by turning the relief screw counterclockwise. Then tighten the pressure relief screw and repeat Step 6 (at least twice) to make sure the reading is repeatable within the specifications of the pressure relief cap. 8. If the pressure test gauge readings are not within specifications, replace the pressure relief cap. If the pressure test gauge readings are within specifications, perform the cooling system Pressure Test. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) Radiator Hose: Service and Repair Radiator Hoses (Lower) REMOVAL 1. Drain the engine cooling system. 2. Remove inlet side of engine Air Cleaner (ACL). 3. Disconnect the lower radiator hose from the oil filter adapter. 4. Disconnect the lower radiator hose from the degas bottle. 5. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 6. If equipped with engine oil cooler, disconnect the lower radiator hose connections from the oil cooler. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 3076 7. Disconnect the lower radiator hose from the radiator. 1 Pry the locking tab up and out of the slot. 2 Rotate the lower radiator hose. 3 Disconnect and remove the lower radiator hose. INSTALLATION 1. Follow the removal procedure in reverse order. NOTE: ^ If equipped with air suspension, reactivate the system by turning on the air suspension switch. ^ The lower radiator hose does not require rotation for installation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 3077 Radiator Hose: Service and Repair Radiator Hoses (Upper) REMOVAL 1. Partially drain the engine cooling system. 2. Remove the upper radiator hose. 1 Release the hose clamps and slide away from the hose ends. 2 Remove the upper radiator hose. INSTALLATION 1. Install the upper radiator hose. 1 Position the upper radiator hose. 2 Compress and position the hose clamps. NOTE: Make sure that the upper radiator hose is seated in the upper hose support bracket. 2. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Engine View The Cooling Fan Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor ............................................................................................................................... 16-24 Nm (11.8-17.4 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3087 Engine Views Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3088 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Remove the Engine Coolant Temperature sensor (ECT sensor). 1 Disconnect the electrical connector. 2 Remove the engine coolant temperature sensor. INSTALLATION 1. Install the engine coolant temperature sensor. 1 Install the engine coolant temperature sensor. 2 Connect the electrical connector. 2. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Description and Operation Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications Cylinder Head Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor ...................................................................................................................................... 19-25 Nm (14-18 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications > Page 3095 Cylinder Head Temperature Sensor: Locations Engine View The Cylinder Head Temperature Sensor is located on the top front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications > Page 3096 Cylinder Head Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the cylinder head temperature sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. Install the CHT sensor. 1 Install the sensor. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Service and Repair Temperature Sensor (Gauge): Service and Repair REMOVAL 1. Partially drain the engine cooling system. 2. Remove the water temperature indicator sender unit. 1 Disconnect the electrical connector. 2 Remove the water temperature indicator sender unit. INSTALLATION 1. Install the water temperature indicator sender unit. 1 Install the water temperature indicator sender unit. 2 Connect the electrical connector. 2. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Start To Open Temperature ........................................................................................................................................ 87-91° C (188-195° F) Thermostat Full Open Temperature .......................................................................................................................................................... 100° C (212° F) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3106 Thermostat: Testing and Inspection THERMOSTAT-WATER The water thermostat should be replaced only after the following electrical and mechanical tests have been performed. THERMOSTAT-ELECTRICAL TEST CAUTION: Always vent the exhaust to the outside when performing this test. NOTE: The electrical thermostat test is most accurate if performed indoors at less than 37.8°C (100°F) ambient air. This test may be performed 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, remove the Engine Coolant Temperature (ECT) sensor harness connector and attach ECT Sensor "T" Cable as a jumper between the Powertrain Control Module (PCM) and the ECT Sensor. Attach the 73 Digital Multimeter to the ECT Sensor "T" Cable. Voltage values (0-5 V) may now be monitored while the sensor retains its connection to the wiring harness. New Generation STAR (NGS) Tester or the Service Bay Diagnostic System (SPUDS) may be used to monitor the ECT on vehicles equipped with Data Link Connector (DLC). The SODS sequence to use for the screen is: - Toolbox-Electronic Engine Control and DCL-Item. 3. Place the transmission in PARK (Up) or NEUTRAL (N). NOTE: Running this test with the vehicle in gear or with the A/C compressor clutch engaged (running) will cause improper diagnosis. 4. Start the engine and allow the engine to idle throughout this test. Allow the engine to run for 2 minutes, then record the ECT voltage. Record the ECT voltage every 60 seconds. When the ECT voltage trend changes direction or only changes slightly (0.03 voltage or less) from the previous reading, record this as the thermostat opening voltage. Use the voltage and corresponding coolant temperature chart. 5. If the thermostat opening voltage is greater than 0.75 volts and less than 82°C (180°F), replace the water thermostat. 6. If the thermostat opening voltage is less than 0.75 volts and greater than 82°C (180°F), the water thermostat is good and should not be replaced. For further instructions See: Testing and Inspection/Symptom Related Diagnostic Procedures THERMOSTAT-MECHANICAL TEST 1. Remove the water thermostat. 2. Check the water thermostat for seating. Hold the water thermostat up to a lighted background. Leakage of light around the thermostat valve at room temperature indicates that the water thermostat should be replaced. Some water thermostats have a small leakage notch at one location on the perimeter of the thermostat valve, which is considered normal. 3. Immerse the water thermostat in a boiling antifreeze and water mixture. 4. See the General Specifications chart for water thermostat opening temperatures. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3107 Thermostat: Service and Repair REMOVAL 1. Partially drain the engine cooling system. 2. Disconnect the upper radiator hose. 1 Compress and position the constant tension clamp 2 Disconnect the hose and position it out of the way. 3. Remove the upper radiator hose. 4. Remove the water water hose connection. 1 Remove the bolts. 2 Remove the water hose connection. 5. Remove the (A) water thermostat and the (B) O-ring. Discard the (B) O-ring. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3108 1. Use a new (A) O-ring and position the (B) water thermostat in the (C) upper intake manifold. 2. Install the water hose connection. 1 Position the (A) water hose connection on to (B) upper intake manifold. 2 Install the bolts. 3. Connect the upper radiator hose. 1 Position the upper radiator hose. 2 Compress and position the constant tension clamp. NOTE: Make sure that the upper radiator hose is seated in the upper hose bracket. 4. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications Drive Pulley: Specifications DRIVE RATIO Pump Pulley Ratio ............................................................................................................................... ......................................................................... 1.3 TORQUE SPECIFICATIONS Water Pump Pulley Bolts ........................................................................................................................................................... 20-30 Nm (15-22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: Customer Interest Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3123 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3124 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3130 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3131 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Nuts 23-27 Nm (17-19 ft.lb) LH Sequence --- RH Sequence --- Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 3135 Exhaust Manifold: Testing and Inspection Place a straight edge across the exhaust manifold flanges and check for warping with a feeler gauge. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side Exhaust Manifold: Service and Repair Left Side REMOVAL WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Raise and support the vehicle. 2. Remove the front wheel opening moulding. 3. Remove the front fender splash shield. 4. Remove the nut and the brake booster vacuum hose bracket. 5. Disconnect the EGR valve to exhaust manifold tube connections: ^ The EGR backpressure transducer hoses. ^ The EGR valve to exhaust manifold tube upper fitting. ^ The EGR valve to exhaust manifold tube lower fitting and remove the EGR valve to exhaust manifold tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3138 6. Remove the three way catalytic converter to exhaust manifold nuts. 7. Remove the (A) nuts and the (B) exhaust manifold. 8. Remove the exhaust manifold gasket. 9. Clean and inspect the exhaust manifold. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3139 Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3140 Exhaust Manifold: Service and Repair Right Side REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the front wheel opening moulding. 3. Remove the front fender splash shield. 4. Remove the three way catalytic converter to exhaust manifold nuts. 5. Remove the eight (A) nuts and the (B) exhaust manifold. 6. Remove and discard the exhaust manifold gasket. 7. Clean and inspect the exhaust manifold. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3141 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Page 3142 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe: > 98-25-21 > Dec > 98 > Exhaust System Cracks/Breaks Between Muffler/Tailpipe Exhaust Pipe: Customer Interest Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe: > 98-25-21 > Dec > 98 > Exhaust System Cracks/Breaks Between Muffler/Tailpipe Exhaust Pipe: All Technical Service Bulletins Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Page 3156 Exhaust Pipe: Service and Repair REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the muffler to Three Way Catalytic Converter (TWC) pipe clamp. 1 Remove the clamp nuts. 2 Remove the clamp. 3. Remove the exhaust hanger insulators and discard, if damaged. NOTE: The exhaust hanger insulators can be reused if they show no signs of damage. 4. Remove the tailpipe from the exhaust hanger insulator. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Page 3157 5. Remove the muffler and tailpipe assembly. NOTE: It may be necessary to heat the TWC joint to ease removal. INSTALLATION 1. Position the muffler and tailpipe assembly. CAUTION: Do not use oil or grease based lubricants on insulators which deteriorates the rubber. 2. Install the exhaust hanger insulators. NOTE: A soap and water solution will ease installation of the muffler hangers into the rubber tailpipe hanger insulators. 3. Install the tailpipe into the exhaust hanger insulator. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Page 3158 Special Tools 4. Install the muffler to catalytic converter pipe clamp. 1 Position the clamp. 2 Install the nuts. 5. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise Heat Shield: Customer Interest Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 3167 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 3168 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Heat Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3174 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3175 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Page 3176 Heat Shield: Specifications Mounting Bolts ..................................................................................................................................... ......................................... 13-17 Nm (10-13 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest for Muffler: > 98-25-21 > Dec > 98 > Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Muffler: Customer Interest Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Muffler: > 98-25-21 > Dec > 98 > Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Muffler: All Technical Service Bulletins Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 3190 Muffler: Specifications Muffler Inlet Pipe To TWC ........................................................................................................................................................... 47-63 Nm (35-46 ft. lbs.) Muffler To Converter .................................................................................... ................................................................................. 40-55 Nm (30-40 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 3191 Muffler: Service and Repair REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the muffler to Three Way Catalytic Converter (TWC) pipe clamp. 1 Remove the clamp nuts. 2 Remove the clamp. 3. Remove the exhaust hanger insulators and discard, if damaged. NOTE: The exhaust hanger insulators can be reused if they show no signs of damage. 4. Remove the tailpipe from the exhaust hanger insulator. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 3192 5. Remove the muffler and tailpipe assembly. NOTE: It may be necessary to heat the TWC joint to ease removal. INSTALLATION 1. Position the muffler and tailpipe assembly. CAUTION: Do not use oil or grease based lubricants on insulators which deteriorates the rubber. 2. Install the exhaust hanger insulators. NOTE: A soap and water solution will ease installation of the muffler hangers into the rubber tailpipe hanger insulators. 3. Install the tailpipe into the exhaust hanger insulator. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 3193 Special Tools 4. Install the muffler to catalytic converter pipe clamp. 1 Position the clamp. 2 Install the nuts. 5. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 (V8-281 4.6L SOHC (1998)) 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 3201 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 (V8-281 4.6L SOHC (1998)) 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 3202 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 (V8-281 4.6L SOHC (1998)) 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 3203 Engine Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 3204 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 3205 Engine Control Module: Specifications Powertrain Control Module (PCM) Electrical Connector Bolt ................................................................................................ 5.2-7.2 Nm (46.3-64.2 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 3206 Engine Control Module: Locations The Powertrain Control Module is located below the dash, in the right side kick panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3209 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3210 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3211 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3212 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3213 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3214 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3215 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3216 Engine Control Module: Connector Views Power control module (part 1 of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3217 Power control module (part 2 of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3218 Power control module (part 3 of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Powertrain Control Modules (PCMs) are reprogrammable to update calibration levels without having to replace the PCM. The reprogramming may be performed with the PCM installed in the vehicle using the Service Bay Technical System (SBTS). The PCM may also be reprogrammed outside of the vehicle using the New Generation STAR (NGS) and a 15- to 104- Pin Flash Cable (007-00587 or equivalent). The Flash Cable connects between the NGS and the PCM. The proper calibration must be downloaded to the Data Transfer Card through the SBTS. Follow the download instructions displayed on the NGS screen. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3221 Engine Control Module: Reset Procedure NOTE: All OBD II scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears oxygen sensor test data. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation STAR (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTC's. New Generation STAR and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. To reset Keep Alive Random Access Memory, disconnect the battery ground cable for a minimum of 5 minutes. Resetting Keep Alive RAM will clear learned values the PCM has stored for adaptive systems such as idle and fuel trim. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3222 Engine Control Module: Removal and Replacement REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Loosen the bolt and disconnect the electrical connectors. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Remove the bracket clip. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3223 6. Remove the Powertrain Control Module (PCM). INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Main Relay (Computer/Fuel System): Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 3227 Power Distribution Box The Powertrain Control Module Power Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 3232 Power Distribution Box The Fuel Pump Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Main Relay (Computer/Fuel System): Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 3236 Power Distribution Box The Powertrain Control Module Power Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations The ignition control module is integrated within the powertrain control module. It is not a separately replaceable component. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3241 Ignition Control Module: Description and Operation PURPOSE - The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM). The ICM receives engine position and speed information from within the crankshaft position sensor and desired spark advance information from the PCM. OPERATION - The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use within The PCM. - The PCM uses this information to determine which ignition coil to fire, calculating the turn ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3252 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3253 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3259 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3260 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3261 Air Flow Meter/Sensor: Specifications Mass Air Flow Sensor Plate Nuts .................................................................................................................................................. 8-11.5 Nm (5.9-8.5 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3262 Air Flow Meter/Sensor: Locations Engine View The Mass Air Flow Sensor is located in the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3263 Air Flow Meter/Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Open the engine air cleaner. - Disconnect the MAF sensor extension harness connector from the wiring harness. - Release the air cleaner clamp. - Separate the inlet side of the engine Air Cleaner (ACL) from the outlet side of the engine air cleaner. CAUTION: Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. 3. Cut the tape on the wire loom of the extension harness. - Peel back the wire loom from the extension harness near the grommet in the engine air cleaner. 4. Remove the grommet from the outlet side of the engine air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3264 5. Remove the MAF sensor plate and Mass Air Flow sensor (MAF sensor) from the outlet side of the engine engine air cleaner. 6. Disconnect the MAF sensor electrical connector from the extension harness. 7. Separate the MAF sensor plate from the mass air flow sensor. - Remove the nuts from the MAF sensor plate. INSTALLATION CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation There is no actual Barometric Pressure Sensor on this vehicle. The Mass Air Flow Sensor calculates a value for the barometric pressure and sends this information to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt ......................................................................................................................................................... 8-12 Nm (71-106 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3271 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located in front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3272 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 4.6L shown, 5.4L similar 2. Remove the Camshaft Position sensor (CMP sensor). 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor ............................................................................................................................... 16-24 Nm (11.8-17.4 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3276 Engine Views Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3277 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Remove the Engine Coolant Temperature sensor (ECT sensor). 1 Disconnect the electrical connector. 2 Remove the engine coolant temperature sensor. INSTALLATION 1. Install the engine coolant temperature sensor. 1 Install the engine coolant temperature sensor. 2 Connect the electrical connector. 2. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Engine View The Crankshaft Position Sensor is located at the lower front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3281 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the accessory drive belt. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Disconnect the Crankshaft Position (CKP) electrical connector. 4. Disconnect the A/C compressor. 1 Remove the bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the (CKP) sensor bolt and the crankshaft position sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3282 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications Cylinder Head Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor ...................................................................................................................................... 19-25 Nm (14-18 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications > Page 3286 Cylinder Head Temperature Sensor: Locations Engine View The Cylinder Head Temperature Sensor is located on the top front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications > Page 3287 Cylinder Head Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the cylinder head temperature sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. Install the CHT sensor. 1 Install the sensor. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Engine View The Intake Air Temperature Sensor is located on the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 3291 Intake Air Temperature Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls. 1. Disconnect the battery ground cable. 2. Disconnect the IAT sensor electrical connector. 3. Remove the Intake Air Temperature sensor (IAT sensor). INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor (KS) .............................................................................................................................. ............................................. 15-20 Nm (11-15 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3295 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Knock Sensor (KS). 1 Disconnect the electrical connector. 2 Remove the knock sensor. INSTALLATION 1. Install the knock sensor. 1 Install the knock sensor. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Oxygen Sensor: Customer Interest PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3304 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3305 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3306 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3312 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3313 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3314 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3315 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3316 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3317 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3318 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3319 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3320 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3321 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3322 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3323 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3324 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3325 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3326 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Oxygen Sensor: All Technical Service Bulletins PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3331 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3332 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3333 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3339 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3340 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3341 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3342 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3343 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3344 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3345 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3346 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3347 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3348 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3349 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3350 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3351 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3352 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3353 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3354 Oxygen Sensor: Specifications Heated Oxygen Sensor (Front or Rear) ............................................................................................................................................ 36-46 Nm (26-34 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 3357 Exhaust System Component Location - 4.6L Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3360 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3361 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3362 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3363 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3364 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3365 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3366 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3367 Oxygen Sensor: Connector Views Ford does not provide connector views for this vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front Oxygen Sensor: Service and Repair Front Oxygen Sensor Wrench REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Disconnect the two HO2S electrical connectors. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Use the Oxygen Sensor Wrench to remove the Heated Oxygen Sensors (HO2S). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front > Page 3370 INSTALLATION 1. Install and tighten the heated oxygen sensors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front > Page 3371 Oxygen Sensor: Service and Repair Rear Oxygen Sensor Wrench REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Remove the rear Heated Oxygen Sensor (HO2S). 1 Disconnect the electrical connectors. 2 Use the Oxygen Sensor Wrench to remove the heated oxygen sensors. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications EGR Transducer Nuts ......................................................................................................................... ........................................... 2.2-5.5 Nm (22-49 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3375 Pressure Feedback Exhaust Sensor: Locations Engine View The Differential Pressure Feedback EGR Sensor is located at the right side of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3376 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the EGR transducer. 1 Remove the EGR transducer hoses. 2 Disconnect the EGR transducer electrical connector. 3 Remove the nuts. 4 Remove the EGR transducer. 4.6L engine is shown; 5.4L engine is similar INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position (TP) Sensor Bolts ............................................................................................................................................... 2.8-3.4 Nm (25-30 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3380 Throttle Position Sensor: Locations Engine View The Throttle Position Sensor is attached to the throttle body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3381 Throttle Position Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the splash shield. 3. Remove the Throttle Position sensor (TP sensor). 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the throttle position sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3382 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS Transmission Range (TR) Sensor Bolts .................................................................................................................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 3386 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at the left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 3387 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 3388 Transmission Position Switch/Sensor: Description and Operation DIGITAL TRANSMISSION RANGE (TR) SENSOR The Digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in Park and Neutral, the back-up lamp circuit in Reverse and the neutral sense circuit (4x4 only) in Neutral. The digital TR sensor also opens and closes a set of four switches that are monitored by the powertrain control module to determine the position of the manual lever (P,R,N,D,2,1). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 3389 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Disconnect the digital TR electrical connector. 6. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 7. Loosen the digital TR bolts. 8. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 3390 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. 9. Tighten the bolts. 10. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 11. With the manual lever in overdrive connect the shift lever control cable. 12. Install the digital TR sensor electrical connector. 13. Lower the vehicle. 14. Connect the battery ground cable. 15. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications TORQUE SPECIFICATIONS Vehicle Speed Sensor (VSS) Bolt ........................................................................................................................................ 11-13 Nm (98-115 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 3394 Vehicle Speed Sensor: Locations Transmission View The Vehicle Speed Sensor is located at the left rear of transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3397 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3398 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3399 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3400 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3401 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3402 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3403 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3404 Vehicle Speed Sensor: Service and Repair REMOVAL 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise and support the vehicle. 4. Remove the Vehicle Speed Sensor (VSS). 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the VSS. 5. Remove the Vehicle Speed Sensor (VSS) drive gear. 1 Remove the retaining clip. 2 Remove the driven gear. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3405 1. Install Vehicle Speed Sensor (VSS) drive gear. 1 Install the driven gear. 2 Install the retaining clip. 2. Install the VSS. 1 Install the VSS. 2 Install the bolt. 3 Connect the electrical connector. 3. Lower the vehicle. 4. Connect the battery ground cable. 5. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications EGR Transducer Nuts ......................................................................................................................... ........................................... 2.2-5.5 Nm (22-49 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3410 Pressure Feedback Exhaust Sensor: Locations Engine View The Differential Pressure Feedback EGR Sensor is located at the right side of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3411 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the EGR transducer. 1 Remove the EGR transducer hoses. 2 Disconnect the EGR transducer electrical connector. 3 Remove the nuts. 4 Remove the EGR transducer. 4.6L engine is shown; 5.4L engine is similar INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3421 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3422 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3428 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3429 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3430 Air Flow Meter/Sensor: Specifications Mass Air Flow Sensor Plate Nuts .................................................................................................................................................. 8-11.5 Nm (5.9-8.5 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3431 Air Flow Meter/Sensor: Locations Engine View The Mass Air Flow Sensor is located in the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3432 Air Flow Meter/Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Open the engine air cleaner. - Disconnect the MAF sensor extension harness connector from the wiring harness. - Release the air cleaner clamp. - Separate the inlet side of the engine Air Cleaner (ACL) from the outlet side of the engine air cleaner. CAUTION: Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. 3. Cut the tape on the wire loom of the extension harness. - Peel back the wire loom from the extension harness near the grommet in the engine air cleaner. 4. Remove the grommet from the outlet side of the engine air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3433 5. Remove the MAF sensor plate and Mass Air Flow sensor (MAF sensor) from the outlet side of the engine engine air cleaner. 6. Disconnect the MAF sensor electrical connector from the extension harness. 7. Separate the MAF sensor plate from the mass air flow sensor. - Remove the nuts from the MAF sensor plate. INSTALLATION CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications Inertia Fuel Shutoff Switch: Specifications Inertia Fuel Shutoff Switch Bolts ................................................................................................................................................... 1.6-2.2 Nm (15-19 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 3437 Inertia Fuel Shutoff Switch: Locations The inertia fuel shutoff switch is located in the right kick panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 3438 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. The IFS 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 3439 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the RH cowl side trim panel. 3. Disconnect the inertia fuel shutoff switch electrical connector. 4. Remove the inertia fuel shutoff switch. 1 Remove the bolts. 2 Remove the inertia fuel shutoff switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position (TP) Sensor Bolts ............................................................................................................................................... 2.8-3.4 Nm (25-30 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3443 Throttle Position Sensor: Locations Engine View The Throttle Position Sensor is attached to the throttle body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3444 Throttle Position Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the splash shield. 3. Remove the Throttle Position sensor (TP sensor). 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the throttle position sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3445 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt ......................................................................................................................................................... 8-12 Nm (71-106 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3450 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located in front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3451 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 4.6L shown, 5.4L similar 2. Remove the Camshaft Position sensor (CMP sensor). 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Engine View The Crankshaft Position Sensor is located at the lower front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3455 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the accessory drive belt. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Disconnect the Crankshaft Position (CKP) electrical connector. 4. Disconnect the A/C compressor. 1 Remove the bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the (CKP) sensor bolt and the crankshaft position sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3456 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3462 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3463 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3464 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3465 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3466 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3467 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Functional Ignition Switch Lock Cylinder: Service and Repair Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key and turn to the RUN position. (2) Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Functional > Page 3470 Ignition Switch Lock Cylinder: Service and Repair Non-Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Functional > Page 3471 - Thoroughly clean all drill shavings from the steering column and inspect for damage. INSTALLATION 1. To install, reverse the removal procedure, using a new ignition switch lock cylinder. - Verify ignition switch lock cylinder operation. NOTE: - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. - Use a new ignition switch lock cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor (KS) .............................................................................................................................. ............................................. 15-20 Nm (11-15 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3475 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Knock Sensor (KS). 1 Disconnect the electrical connector. 2 Remove the knock sensor. INSTALLATION 1. Install the knock sensor. 1 Install the knock sensor. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve .................................................................................................................. .................................................. 7.75 Nm (68.6 Lb/In) Fuel Pressure Relief Valve Cap ..................... ........................................................................................................................................... 0.6 Nm (5.3 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3481 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE 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. 1. Perform the fuel pressure release procedure. 2. Remove the (A) fuel pressure relief valve with the (B) fuel pressure relief valve cap. INSTALLATION 1. Install fuel pressure relief valve. 2. Install the fuel pressure relief valve cap. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 680 - 830 RPM Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet engine Air Cleaner (ACL) aside. 2. Remove the (A) air cleaner element from the (B) open end of the inlet engine air cleaner. INSTALLATION 1. Install the air cleaner element. 2. Position the engine air cleaner aligning the alignment tab. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet engine air cleaner has an alignment tab which fits into a slot on the outlet engine air cleaner. This ensures a good seal and keeps unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3489 3. Close the air cleaner clamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 EFI/CFI Fuel Pressure Gauge WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place the fuel in a suitable container. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 3497 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 3498 Firing Order 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order Firing Order: 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair REMOVAL CAUTION: Spark plug wires must be connected to the proper ignition coil terminal and spark plug. Mark the spark plug wire locations. 1. Grasp the spark plug boot firmly and use a twisting, pulling motion to disconnect the spark plug wires from the spark plugs. 2. Squeeze the locking tabs and disconnect the spark plug wire from the ignition coil. INSTALLATION 1. Apply Silicone Brake Caliper Grease Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire boots. 2. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark Plug Torque ............................................................................................................................... ............................................. 9-20 Nm (80-178 Lb/In) Spark Plug Gap ............................................... ....................................................................................................................... 1.32-1.42 mm (0.052-0.056 in) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 3510 Spark Plug: Specifications Torque Spark Plug Torque ............................................................................................................................... ............................................. 9-20 Nm (80-178 Lb/In) Spark Plug Gap ............................................... ....................................................................................................................... 1.32-1.42 mm (0.052-0.056 in) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3511 Spark Plug: Application and ID RH Original Spark Plug ....................................................................................................................... ........................................................ AWSF32PG (a) LH Original Spark Plug ..................................... ............................................................................................................................................. AWSF32P (a) Replacement Spark Plug (Either Side) ......................................................................................................................................................... AWSF32PP (a) (a) If a spark plug is removed for examination, it must be reinstalled in the same cylinder. If a new spark plug needs to be installed, use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3512 Spark Plug: Service and Repair REMOVAL CAUTION: Spark plug wires must be connected to the proper ignition coil terminal and spark plug. Mark the spark plug wire locations. NOTE: Use compressed air to remove any debris from the spark plug well before removing the spark plugs. 1. Grasp the spark plug boot firmly and use a twisting, pulling motion to disconnect the spark plug wires from the spark plugs. 2. Remove the spark plugs. NOTE: Remove any foreign debris from the spark plug wells with compressed air. 3. Inspect the spark plug. INSTALLATION 1. Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire boots. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3513 2. Adjust the spark plug gap as required. 3. Install the spark plugs. 4. Connect the spark plug wires. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test Compression Check: Testing and Inspection Compression Test 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as Compression Tester in No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, use the auxiliary starter switch to 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test > Page 3519 Compression Check: Testing and Inspection Interpreting Compression Readings 1. If compression improves considerably, the piston rings require service. 2. If compression does not improve, the valves are sticking or seating improperly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on the piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil and/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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test > Page 3520 Compression Check: Testing and Inspection Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Use the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil SAE 1OW-40XO-1OW40-QSP meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer does not indicate whether this vehicle has adjustable or non-adjustable valves. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3533 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3534 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3540 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3541 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3542 Air Flow Meter/Sensor: Specifications Mass Air Flow Sensor Plate Nuts .................................................................................................................................................. 8-11.5 Nm (5.9-8.5 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3543 Air Flow Meter/Sensor: Locations Engine View The Mass Air Flow Sensor is located in the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3544 Air Flow Meter/Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Open the engine air cleaner. - Disconnect the MAF sensor extension harness connector from the wiring harness. - Release the air cleaner clamp. - Separate the inlet side of the engine Air Cleaner (ACL) from the outlet side of the engine air cleaner. CAUTION: Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. 3. Cut the tape on the wire loom of the extension harness. - Peel back the wire loom from the extension harness near the grommet in the engine air cleaner. 4. Remove the grommet from the outlet side of the engine air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3545 5. Remove the MAF sensor plate and Mass Air Flow sensor (MAF sensor) from the outlet side of the engine engine air cleaner. 6. Disconnect the MAF sensor electrical connector from the extension harness. 7. Separate the MAF sensor plate from the mass air flow sensor. - Remove the nuts from the MAF sensor plate. INSTALLATION CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Engine View The Intake Air Temperature Sensor is located on the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3549 Intake Air Temperature Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls. 1. Disconnect the battery ground cable. 2. Disconnect the IAT sensor electrical connector. 3. Remove the Intake Air Temperature sensor (IAT sensor). INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): Customer Interest Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 3558 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 3559 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 3565 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 3566 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation There is no actual Barometric Pressure Sensor on this vehicle. The Mass Air Flow Sensor calculates a value for the barometric pressure and sends this information to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt ......................................................................................................................................................... 8-12 Nm (71-106 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3573 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located in front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3574 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 4.6L shown, 5.4L similar 2. Remove the Camshaft Position sensor (CMP sensor). 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor ............................................................................................................................... 16-24 Nm (11.8-17.4 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3578 Engine Views Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3579 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Remove the Engine Coolant Temperature sensor (ECT sensor). 1 Disconnect the electrical connector. 2 Remove the engine coolant temperature sensor. INSTALLATION 1. Install the engine coolant temperature sensor. 1 Install the engine coolant temperature sensor. 2 Connect the electrical connector. 2. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Engine View The Crankshaft Position Sensor is located at the lower front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3583 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the accessory drive belt. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Disconnect the Crankshaft Position (CKP) electrical connector. 4. Disconnect the A/C compressor. 1 Remove the bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the (CKP) sensor bolt and the crankshaft position sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3584 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Instrument Panel View The Data Link Connector is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3590 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3591 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3592 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3593 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3594 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3595 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3596 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3597 Data Link Connector Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3602 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3603 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3604 Engine Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3605 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3606 Engine Control Module: Specifications Powertrain Control Module (PCM) Electrical Connector Bolt ................................................................................................ 5.2-7.2 Nm (46.3-64.2 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3607 Engine Control Module: Locations The Powertrain Control Module is located below the dash, in the right side kick panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3610 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3611 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3612 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3613 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3614 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3615 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3616 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3617 Engine Control Module: Connector Views Power control module (part 1 of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3618 Power control module (part 2 of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3619 Power control module (part 3 of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Powertrain Control Modules (PCMs) are reprogrammable to update calibration levels without having to replace the PCM. The reprogramming may be performed with the PCM installed in the vehicle using the Service Bay Technical System (SBTS). The PCM may also be reprogrammed outside of the vehicle using the New Generation STAR (NGS) and a 15- to 104- Pin Flash Cable (007-00587 or equivalent). The Flash Cable connects between the NGS and the PCM. The proper calibration must be downloaded to the Data Transfer Card through the SBTS. Follow the download instructions displayed on the NGS screen. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3622 Engine Control Module: Reset Procedure NOTE: All OBD II scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears oxygen sensor test data. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation STAR (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTC's. New Generation STAR and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. To reset Keep Alive Random Access Memory, disconnect the battery ground cable for a minimum of 5 minutes. Resetting Keep Alive RAM will clear learned values the PCM has stored for adaptive systems such as idle and fuel trim. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3623 Engine Control Module: Removal and Replacement REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Loosen the bolt and disconnect the electrical connectors. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Remove the bracket clip. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3624 6. Remove the Powertrain Control Module (PCM). INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications Cylinder Head Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor ...................................................................................................................................... 19-25 Nm (14-18 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications > Page 3628 Cylinder Head Temperature Sensor: Locations Engine View The Cylinder Head Temperature Sensor is located on the top front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications > Page 3629 Cylinder Head Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the cylinder head temperature sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. Install the CHT sensor. 1 Install the sensor. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications Idle Air Control (IAC) Valve Bolts .......................................................................................................................................... 3.1-4.3 Nm (27.6-38.3 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3633 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 3. Remove IAC valve. 1 Disconnect the electrical connector. 2 Disconnect the throttle bypass hose. 3 Remove the bolts. 4 Remove the Idle Air Control valve (IAC valve). 5 Remove and discard the idle air control gasket. INSTALLATION 1. Position the idle air control valve and a new idle air control gasket and tighten the bolts in 2 steps. - Step 1: 3-10 Nm (71-89 lb/in) - Step 2: Rotate 90 degrees Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3634 2. Connect the IAC electrical connector. 3. Connect the throttle bypass hose. 4. Connect the battery ground cable. 5. Install the accelerator control splash shield. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Specifications Multiplex Communication Network: Specifications Battery Ground Cable .......................................................................................................................... .............................................. 7-10 N.m (62-89 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions Multiplex Communication Network: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3640 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3641 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3642 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3643 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3644 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3645 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3646 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3647 Multiplex Communication Network Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Page 3648 Multiplex Communication Network: Description and Operation The vehicle has two module communications networks. The Powertrain Control Module (PCM) is connected to the Standard Corporate Protocol (SCP) link. The Integrated Air Bag Module (IABM) and any of the optional modules are connected to the ISO 9141 Link via a single wire. Both networks can be connected to New Generation STAR (NGS) Tester at one connector called the Data Link Connector (DLC). This makes troubleshooting these Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Page 3649 systems easier by allowing one smart tester to be able to diagnose and control any module on the two networks from one connector. The DLC can be found under the instrument panel between the steering column and the radio. The diagnostic communication network does not permit inter-module communication. When NGS Tester communicates to modules on the diagnostic communication network, NGS Tester must ask for all information; the modules cannot initiate communications. The PCM is on the multiplex communication network. The PCM controls the engine for better fuel economy emissions control, and failure mode detection and storage. The IABM is on the diagnostic communication network. The IABM controls the deployment of the air bags based on sensor input. The Electronic Automatic Temperature Control (EATC) module is on the diagnostic communication network. The EATC module controls automatic climate functions that maintain the vehicle cabin temperature at a constant setting. The Generic Electronic Module (GEM) is on the diagnostic communication network. The GEM controls a variety of systems: ^ Windshield wipers. ^ Courtesy lamps. ^ 4-wheel shift on the fly. ^ Warning chimes. ^ One touch down power windows. The Remote Anti-theft Personality (RAP) module is on the diagnostic communication network. The RAP module controls the remote entry, interior lamp illumination signal to the GEM, and panic alarm from the keyless entry remote. The Four-wheel Anti-lock Brake System (4WABS) is on the diagnostic communication network. The 4WABS controls brake pressure to the four wheels to keep the vehicle under control while braking. The Passive Anti-Theft System (PATS) module is on the multiplex communication network. The PATS module contains circuitry to connect the vehicle electrical system, the transceiver module, the vehicle module communications network and the vehicle theft indicator located in the instrument cluster. The PATS module uses a microprocessor to control the system functions. The PATS module microprocessor stores the ignition key codes in non-volatile memory. The PATS module can be diagnosed through the DLC. The following describes the rear and four-wheel air suspension modules: A microcontroller-based electronic 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. The module controls vehicle height adjustments by monitoring two height sensors, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals, and the brake switch. The module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing of the vehicle and module. The control module is mounted in the passenger compartment inside the instrument panel above the radio and temperature controls. The air suspension system control module monitors and controls the system through a 32-pin two-way connector. It is keyed so that the control module cannot be plugged into an incorrect harness. There are two sides of the harness connection to the module. Each is uniquely colored and keyed to prevent reversal of connections. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis Multiplex Communication Network: Flow of Diagnosis 1. Verify the customer concern by operating the system in question. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Fuse(s) ^ Damaged wiring harness ^ Loose or corroded connections ^ Four-Wheel Anti-lock Brake System (4WABS) module ^ Electronic Automatic Temperature Control (EATC) module ^ Driver Seat Module (DSM) ^ Remote Anti-theft Personality (RAP) module ^ Generic Electronic Module (GEM) ^ Integrated Air Bag Module (IABM) ^ Powertrain Control Module (PCM) ^ Four-Wheel Air Suspension Module (4WAS) ^ Anti-lock brake control module ^ Passive Anti-Theft System (PATS) module 3. If the concern remains after the inspection, connect New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from NGS Tester menu. If NGS Tester does not communicate with the vehicle: ^ Check that the program card is properly installed. ^ Check the connections to the vehicle. ^ Check the ignition switch position. If NGS Tester still does not communicate with the vehicle, go to Pinpoint Test M. See: Pinpoint Tests/M : No Module/Network Communication Go to Pinpoint Test PC. See: Initial Inspection and Diagnostic Overview/System Precheck Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3652 Multiplex Communication Network: Initial Inspection and Diagnostic Overview PC1 Inspection and Verification (Start Here) 1. Verify the customer concern by operating the system in question. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Fuse(s) ^ Damaged wiring harness ^ Loose or corroded connections ^ Four-Wheel Anti-lock Brake System (4WABS) module ^ Electronic Automatic Temperature Control (EATC) module ^ Driver Seat Module (DSM) ^ Remote Anti-theft Personality (RAP) module ^ Generic Electronic Module (GEM) ^ Integrated Air Bag Module (IABM) ^ Powertrain Control Module (PCM) ^ Four-Wheel Air Suspension Module (4WAS) ^ Anti-lock brake control module ^ Passive Anti-Theft System (PATS) module 3. If the concern remains after the inspection, connect New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from NGS Tester menu. If NGS Tester does not communicate with the vehicle: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3653 ^ Check that the program card is properly installed. ^ Check the connections to the vehicle. ^ Check the ignition switch position. If NGS Tester still does not communicate with the vehicle, go to Pinpoint Test M. See: Pinpoint Tests/M : No Module/Network Communication Go to Pinpoint Test PC. See: System Precheck Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3654 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3655 Multiplex Communication Network: Pinpoint Tests A1 - A2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3656 A3 - A5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3657 B1 - B2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3658 B3 - B5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3659 C1 - C3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3660 D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3661 D2 - D3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3662 E1 - E3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3663 E4 F : No Response To NGS Tester From Driver Seat Module F1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3664 F2 - F3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3665 F4 - F5 G : No Response to NGS Tester From Powertrain Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3666 G1 - G2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3667 G3 - G4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3668 G5 H : No Response to NGS Tester From Anti-Theft Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3669 H1 - H2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3670 H3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3671 H4 - H5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3672 H6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3673 J1 - J2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3674 J3 - J4 K : No Module/Network Communication - SCP Link Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3675 K1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3676 K2 - K3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3677 K4 - K5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3678 K6 - K7 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3679 K8 - K10 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3680 K11 - K12 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3681 K13 - K14 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3682 K15 - K16 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3683 K17 - K18 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3684 K19 - K20 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3685 K21 - K22 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3686 K23 - K24 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3687 K25 - K27 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3688 K28 - K29 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3689 K30 - K31 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3690 K32 - K33 L : No Module/Network Communication - ISO 9141 Link Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3691 L1 - L3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3692 L4 - L5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3693 L6 - L7 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3694 L8 - L9 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3695 L10 - L11 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3696 L12 - L13 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3697 L14 - L15 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3698 L16 - L17 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3699 L18 - L19 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3700 L20 - L22 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3701 M1 - M3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3702 M4 - M6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3703 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Service and Repair > Communication Circuit Wiring Repair Multiplex Communication Network: Service and Repair Communication Circuit Wiring Repair Master Heat Gun Special Tool(s) 1. Disconnect the battery ground cable. 2. Strip the wires. 3. Solder the wires. 1 Install the heat shrink tube. 2 Twist the wires together. 3 Solder the wires together. NOTE: Use Rosin Core Mildly Activated (RMA) solder, not acid core solder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Service and Repair > Communication Circuit Wiring Repair > Page 3706 4. Bend the wires back in a straight line. NOTE: Wait for the solder to cool before moving the wires. 5. Position the (A) heat shrink tube over the (B) wire repair. ^ Overlap the heat shrink tube on both wires. 6. Use Master Heat Gun to heat the repaired area until adhesive flows out both ends of the heat shrink tube. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Service and Repair > Communication Circuit Wiring Repair > Page 3707 Multiplex Communication Network: Service and Repair Wiring Repair Requirements Heat Shrink Tube Overlap ................................................................................................................... ......................................................... 12.7 mm (0.5 in) Wire Insulation Removal Length (Twist Side) ............................................................................................................................................. 37.2 mm (1.5 in) Wire Insulation Removal Length (Receiving Side) .................................................................................................................................... 19.5 mm (0.75 in) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor (KS) .............................................................................................................................. ............................................. 15-20 Nm (11-15 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3711 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Knock Sensor (KS). 1 Disconnect the electrical connector. 2 Remove the knock sensor. INSTALLATION 1. Install the knock sensor. 1 Install the knock sensor. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3715 Power Distribution Box The Powertrain Control Module Power Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Oxygen Sensor: Customer Interest PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3727 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3728 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3729 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3735 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3736 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3737 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3738 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3739 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3740 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3741 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3742 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3743 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3744 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3745 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3746 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3747 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3748 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3749 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Oxygen Sensor: All Technical Service Bulletins PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3754 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3755 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3756 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3762 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3763 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3764 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3765 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3766 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3767 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3768 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3769 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3770 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3771 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3772 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3773 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3774 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3775 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3776 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3777 Oxygen Sensor: Specifications Heated Oxygen Sensor (Front or Rear) ............................................................................................................................................ 36-46 Nm (26-34 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 3780 Exhaust System Component Location - 4.6L Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3783 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3784 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3785 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3786 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3787 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3788 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3789 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3790 Oxygen Sensor: Connector Views Ford does not provide connector views for this vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front Oxygen Sensor: Service and Repair Front Oxygen Sensor Wrench REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Disconnect the two HO2S electrical connectors. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Use the Oxygen Sensor Wrench to remove the Heated Oxygen Sensors (HO2S). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front > Page 3793 INSTALLATION 1. Install and tighten the heated oxygen sensors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front > Page 3794 Oxygen Sensor: Service and Repair Rear Oxygen Sensor Wrench REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Remove the rear Heated Oxygen Sensor (HO2S). 1 Disconnect the electrical connectors. 2 Use the Oxygen Sensor Wrench to remove the heated oxygen sensors. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications EGR Transducer Nuts ......................................................................................................................... ........................................... 2.2-5.5 Nm (22-49 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3798 Pressure Feedback Exhaust Sensor: Locations Engine View The Differential Pressure Feedback EGR Sensor is located at the right side of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3799 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the EGR transducer. 1 Remove the EGR transducer hoses. 2 Disconnect the EGR transducer electrical connector. 3 Remove the nuts. 4 Remove the EGR transducer. 4.6L engine is shown; 5.4L engine is similar INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 3805 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 (V8-281 4.6L SOHC (1998)) 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 3806 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 (V8-281 4.6L SOHC (1998)) 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 3807 Engine Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 3808 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 3809 Engine Control Module: Specifications Powertrain Control Module (PCM) Electrical Connector Bolt ................................................................................................ 5.2-7.2 Nm (46.3-64.2 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 3810 Engine Control Module: Locations The Powertrain Control Module is located below the dash, in the right side kick panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3813 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3814 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3815 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3816 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3817 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3818 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3819 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3820 Engine Control Module: Connector Views Power control module (part 1 of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3821 Power control module (part 2 of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3822 Power control module (part 3 of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Powertrain Control Modules (PCMs) are reprogrammable to update calibration levels without having to replace the PCM. The reprogramming may be performed with the PCM installed in the vehicle using the Service Bay Technical System (SBTS). The PCM may also be reprogrammed outside of the vehicle using the New Generation STAR (NGS) and a 15- to 104- Pin Flash Cable (007-00587 or equivalent). The Flash Cable connects between the NGS and the PCM. The proper calibration must be downloaded to the Data Transfer Card through the SBTS. Follow the download instructions displayed on the NGS screen. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3825 Engine Control Module: Reset Procedure NOTE: All OBD II scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears oxygen sensor test data. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation STAR (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTC's. New Generation STAR and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. To reset Keep Alive Random Access Memory, disconnect the battery ground cable for a minimum of 5 minutes. Resetting Keep Alive RAM will clear learned values the PCM has stored for adaptive systems such as idle and fuel trim. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3826 Engine Control Module: Removal and Replacement REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Loosen the bolt and disconnect the electrical connectors. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Remove the bracket clip. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3827 6. Remove the Powertrain Control Module (PCM). INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 3831 Power Distribution Box The Powertrain Control Module Power Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3841 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3842 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3848 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3849 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3850 Air Flow Meter/Sensor: Specifications Mass Air Flow Sensor Plate Nuts .................................................................................................................................................. 8-11.5 Nm (5.9-8.5 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3851 Air Flow Meter/Sensor: Locations Engine View The Mass Air Flow Sensor is located in the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3852 Air Flow Meter/Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Open the engine air cleaner. - Disconnect the MAF sensor extension harness connector from the wiring harness. - Release the air cleaner clamp. - Separate the inlet side of the engine Air Cleaner (ACL) from the outlet side of the engine air cleaner. CAUTION: Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. 3. Cut the tape on the wire loom of the extension harness. - Peel back the wire loom from the extension harness near the grommet in the engine air cleaner. 4. Remove the grommet from the outlet side of the engine air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3853 5. Remove the MAF sensor plate and Mass Air Flow sensor (MAF sensor) from the outlet side of the engine engine air cleaner. 6. Disconnect the MAF sensor electrical connector from the extension harness. 7. Separate the MAF sensor plate from the mass air flow sensor. - Remove the nuts from the MAF sensor plate. INSTALLATION CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation There is no actual Barometric Pressure Sensor on this vehicle. The Mass Air Flow Sensor calculates a value for the barometric pressure and sends this information to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt ......................................................................................................................................................... 8-12 Nm (71-106 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3860 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located in front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3861 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 4.6L shown, 5.4L similar 2. Remove the Camshaft Position sensor (CMP sensor). 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor ............................................................................................................................... 16-24 Nm (11.8-17.4 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3865 Engine Views Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3866 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Remove the Engine Coolant Temperature sensor (ECT sensor). 1 Disconnect the electrical connector. 2 Remove the engine coolant temperature sensor. INSTALLATION 1. Install the engine coolant temperature sensor. 1 Install the engine coolant temperature sensor. 2 Connect the electrical connector. 2. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Engine View The Crankshaft Position Sensor is located at the lower front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3870 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the accessory drive belt. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Disconnect the Crankshaft Position (CKP) electrical connector. 4. Disconnect the A/C compressor. 1 Remove the bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the (CKP) sensor bolt and the crankshaft position sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3871 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications Cylinder Head Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor ...................................................................................................................................... 19-25 Nm (14-18 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications > Page 3875 Cylinder Head Temperature Sensor: Locations Engine View The Cylinder Head Temperature Sensor is located on the top front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Cylinder Head Temperature Sensor <--> [Engine Temperature Sensor] > Component Information > Specifications > Page 3876 Cylinder Head Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the cylinder head temperature sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. Install the CHT sensor. 1 Install the sensor. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Engine View The Intake Air Temperature Sensor is located on the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3880 Intake Air Temperature Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls. 1. Disconnect the battery ground cable. 2. Disconnect the IAT sensor electrical connector. 3. Remove the Intake Air Temperature sensor (IAT sensor). INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor (KS) .............................................................................................................................. ............................................. 15-20 Nm (11-15 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3884 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Knock Sensor (KS). 1 Disconnect the electrical connector. 2 Remove the knock sensor. INSTALLATION 1. Install the knock sensor. 1 Install the knock sensor. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Oxygen Sensor: Customer Interest PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3893 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3894 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3895 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3901 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3902 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3903 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3904 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3905 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3906 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3907 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3908 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3909 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3910 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3911 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3912 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3913 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3914 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3915 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Oxygen Sensor: All Technical Service Bulletins PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3920 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3921 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3922 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3928 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3929 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3930 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3931 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3932 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3933 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3934 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3935 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3936 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3937 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3938 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3939 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3940 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3941 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3942 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3943 Oxygen Sensor: Specifications Heated Oxygen Sensor (Front or Rear) ............................................................................................................................................ 36-46 Nm (26-34 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 3946 Exhaust System Component Location - 4.6L Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3949 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3950 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3951 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3952 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3953 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3954 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3955 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3956 Oxygen Sensor: Connector Views Ford does not provide connector views for this vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front Oxygen Sensor: Service and Repair Front Oxygen Sensor Wrench REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Disconnect the two HO2S electrical connectors. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Use the Oxygen Sensor Wrench to remove the Heated Oxygen Sensors (HO2S). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front > Page 3959 INSTALLATION 1. Install and tighten the heated oxygen sensors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Front > Page 3960 Oxygen Sensor: Service and Repair Rear Oxygen Sensor Wrench REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Remove the rear Heated Oxygen Sensor (HO2S). 1 Disconnect the electrical connectors. 2 Use the Oxygen Sensor Wrench to remove the heated oxygen sensors. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications EGR Transducer Nuts ......................................................................................................................... ........................................... 2.2-5.5 Nm (22-49 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3964 Pressure Feedback Exhaust Sensor: Locations Engine View The Differential Pressure Feedback EGR Sensor is located at the right side of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3965 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the EGR transducer. 1 Remove the EGR transducer hoses. 2 Disconnect the EGR transducer electrical connector. 3 Remove the nuts. 4 Remove the EGR transducer. 4.6L engine is shown; 5.4L engine is similar INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position (TP) Sensor Bolts ............................................................................................................................................... 2.8-3.4 Nm (25-30 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3969 Throttle Position Sensor: Locations Engine View The Throttle Position Sensor is attached to the throttle body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3970 Throttle Position Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the splash shield. 3. Remove the Throttle Position sensor (TP sensor). 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the throttle position sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3971 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS Transmission Range (TR) Sensor Bolts .................................................................................................................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3975 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at the left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3976 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3977 Transmission Position Switch/Sensor: Description and Operation DIGITAL TRANSMISSION RANGE (TR) SENSOR The Digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in Park and Neutral, the back-up lamp circuit in Reverse and the neutral sense circuit (4x4 only) in Neutral. The digital TR sensor also opens and closes a set of four switches that are monitored by the powertrain control module to determine the position of the manual lever (P,R,N,D,2,1). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3978 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Disconnect the digital TR electrical connector. 6. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 7. Loosen the digital TR bolts. 8. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3979 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. 9. Tighten the bolts. 10. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 11. With the manual lever in overdrive connect the shift lever control cable. 12. Install the digital TR sensor electrical connector. 13. Lower the vehicle. 14. Connect the battery ground cable. 15. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications TORQUE SPECIFICATIONS Vehicle Speed Sensor (VSS) Bolt ........................................................................................................................................ 11-13 Nm (98-115 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 3983 Vehicle Speed Sensor: Locations Transmission View The Vehicle Speed Sensor is located at the left rear of transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3986 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3987 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3988 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3989 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3990 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3991 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3992 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3993 Vehicle Speed Sensor: Service and Repair REMOVAL 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise and support the vehicle. 4. Remove the Vehicle Speed Sensor (VSS). 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the VSS. 5. Remove the Vehicle Speed Sensor (VSS) drive gear. 1 Remove the retaining clip. 2 Remove the driven gear. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3994 1. Install Vehicle Speed Sensor (VSS) drive gear. 1 Install the driven gear. 2 Install the retaining clip. 2. Install the VSS. 1 Install the VSS. 2 Install the bolt. 3 Connect the electrical connector. 3. Lower the vehicle. 4. Connect the battery ground cable. 5. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position (TP) Sensor Bolts ............................................................................................................................................... 2.8-3.4 Nm (25-30 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3998 Throttle Position Sensor: Locations Engine View The Throttle Position Sensor is attached to the throttle body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3999 Throttle Position Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the splash shield. 3. Remove the Throttle Position sensor (TP sensor). 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the throttle position sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4000 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS Transmission Range (TR) Sensor Bolts .................................................................................................................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4004 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at the left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4005 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4006 Transmission Position Switch/Sensor: Description and Operation DIGITAL TRANSMISSION RANGE (TR) SENSOR The Digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in Park and Neutral, the back-up lamp circuit in Reverse and the neutral sense circuit (4x4 only) in Neutral. The digital TR sensor also opens and closes a set of four switches that are monitored by the powertrain control module to determine the position of the manual lever (P,R,N,D,2,1). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4007 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Disconnect the digital TR electrical connector. 6. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 7. Loosen the digital TR bolts. 8. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4008 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. 9. Tighten the bolts. 10. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 11. With the manual lever in overdrive connect the shift lever control cable. 12. Install the digital TR sensor electrical connector. 13. Lower the vehicle. 14. Connect the battery ground cable. 15. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications TORQUE SPECIFICATIONS Vehicle Speed Sensor (VSS) Bolt ........................................................................................................................................ 11-13 Nm (98-115 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 4012 Vehicle Speed Sensor: Locations Transmission View The Vehicle Speed Sensor is located at the left rear of transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4015 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4016 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4017 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4018 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4019 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4020 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4021 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4022 Vehicle Speed Sensor: Service and Repair REMOVAL 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise and support the vehicle. 4. Remove the Vehicle Speed Sensor (VSS). 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the VSS. 5. Remove the Vehicle Speed Sensor (VSS) drive gear. 1 Remove the retaining clip. 2 Remove the driven gear. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4023 1. Install Vehicle Speed Sensor (VSS) drive gear. 1 Install the driven gear. 2 Install the retaining clip. 2. Install the VSS. 1 Install the VSS. 2 Install the bolt. 3 Connect the electrical connector. 3. Lower the vehicle. 4. Connect the battery ground cable. 5. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: Customer Interest Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 4034 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 4035 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 4041 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 4042 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair Canister Purge Control Valve: Service and Repair REMOVAL 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. 1. Disconnect the fuel vapor management valve electrical connector and the evaporative emissions vacuum control hose. 2. Disconnect the two fuel vapor tubes. 1 Disconnect the evaporative emissions service port-to-fuel vapor management valve tube. 2 Disconnect the throttle body spacer-to-fuel vapor management valve tube. 3. Remove the bolts and remove the valve. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair > Page 4047 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications Evaporative Emission Control Canister: Specifications Evaporative Emissions Canister Nuts ............................................................................................................................................... 15-20 Nm (11-14 Lb/Ft) Evaporative Emissions Canister Bracket ............................................................................................................................................ 8-10 Nm (70-89 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4051 Evaporative Emission Control Canister: Service and Repair REMOVAL 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. 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS MAY BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRING WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the evaporative emissions canister vent valve electrical connector. 3. Loosen the clamp and remove the fuel vapor tube. 4. Remove the nuts and remove canister and bracket assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4052 5. If required, remove the evaporative emissions canister (EVA canister). 1 Remove the bolt. 2 Remove the bracket. 6. If required, remove the retainer. 1 Slide the retainer off the bracket. 7. Remove the evaporative emissions canister vent valve. NOTE: - Inspect and replace the O-ring as necessary. - A twisting and pulling motion is required to remove the evaporative emissions canister vent valve. 8. NOTE: - Inspect and replace the O-ring as necessary. - If required, a twisting and pulling motion is required to remove the inlet fitting. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4053 INSTALLATION 1. Follow the removal procedure in reverse order. CAUTION: The choke plate adjustment swivel assembly must be leak tested prior to installation on vehicle. NOTE: - If equipped with air suspension, reactivate the system by turning on the air suspension switch. - Lubricate the O-ring seals with ESE-M99B144-B "MerPol" or equivalent. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Service and Repair Evaporative Fuel Vapor Return Hose: Service and Repair REMOVAL 1. Disconnect the battery ground cable. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. 2. Disconnect the vapor tube from the fitting. 1 Squeeze the fitting. 2 Disconnect the vapor tube from the fitting. INSTALLATION 1. Inspect the fitting and the tube for damage. 2. Remove any dirt or obstructions. 3. Push the tube into the fitting until it snaps in place. 4. Pull on the connection to make sure the fitting is secure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications EGR Electronic Vacuum Regulator Solenoid: Specifications EGR Vacuum Regulator Solenoid Nuts ......................................................................................................................................... 2.5-5.5 Nm (22-49 Lb/In) EGR Vacuum Regulator Bracket Bolts and Nut .............................................................................................................................. 8-12 Nm (71-106 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 4061 EGR Electronic Vacuum Regulator Solenoid: Service and Repair REMOVAL 1. Remove the EGR vacuum regulator solenoid. 1 Disconnect the vacuum hose. 2 Disconnect the electrical connector. 3 Remove the nuts. 4 Remove the EGR vacuum regulator solenoid. 4.6L engine is shown; 5.4L engine is similar INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications EGR Tube: Specifications EGR Valve Bolts .................................................................................................................................. ......................................... 8-11.5 Nm (71-103 Lb/In) EGR Valve to Exhaust Manifold Tube Fittings ................................................................................................................................ 34-47 Nm (26-34 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 4065 EGR Tube: Service and Repair REMOVAL 1. Remove the EGR valve to exhaust manifold tube. 1 Remove the two EGR transducer tubes. 2 Remove the EGR valve to exhaust manifold tube upper fitting. 3 Remove the (A) EGR valve to exhaust manifold lower tube fitting and the (B) EGR valve to exhaust manifold tube. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications EGR Valve: Specifications EGR Valve Bolts .................................................................................................................................. ......................................... 8-11.5 Nm (71-103 Lb/In) EGR Valve to Exhaust Manifold Tube Fittings ................................................................................................................................ 34-47 Nm (26-34 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 4069 EGR Valve: Service and Repair REMOVAL 1. Disconnect the EGR valve vacuum hose. 2. Remove the (A) nut and the (B) brake booster tube bracket. 3. Disconnect the EGR valve-to-exhaust manifold tube upper fitting. 4. Remove the EGR valve. 1 Remove the bolts. 2 Remove the EGR valve and the EGR valve gasket. Discard the EGR valve gasket. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 4070 INSTALLATION 1. Follow the removal procedure in reverse order. NOTE: Install a new EGR valve gasket. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications EGR Transducer Nuts ......................................................................................................................... ........................................... 2.2-5.5 Nm (22-49 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4074 Pressure Feedback Exhaust Sensor: Locations Engine View The Differential Pressure Feedback EGR Sensor is located at the right side of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4075 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the EGR transducer. 1 Remove the EGR transducer hoses. 2 Disconnect the EGR transducer electrical connector. 3 Remove the nuts. 4 Remove the EGR transducer. 4.6L engine is shown; 5.4L engine is similar INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > Customer Interest for PCV Valve Hose: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold PCV Valve Hose: Customer Interest Engine - High Idle and Sticking Throttle When Cold Article No. 01-21-12 10/29/01 ^ IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES ---- VEHICLES BUILT 12/2/1997 THROUGH 7/15/1999 EQUIPPED WITH 5.4L ENGINE ^ ENGINE - 5.4L - PCV SYSTEM ICING - VEHICLES BUILT 12/2/1997 THROUGH 7/15/1999 ONLY FORD: 1998-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1999 NAVIGATOR This article is being republished in its entirety to update the Service Procedure, Service Parts and the model years involved. ISSUE In rare instances, throttle sticking may occur on a few vehicles in very cold ambient temperatures after operating at steady speed or extended idle for a period of time. This may be due to ice build-up from moisture in the Positive Crankcase Ventilation (PCV) gas on the throttle plate or throttle body. ACTION Verify the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, check for evidence of PCV system backflow. Refer to the following Service Procedure for details. SERVICE PROCEDURE Inspect the inside of the clean air tube at the PCV closure hose connection for presence of moisture, oil, or oily stains. If evidence of PCV system backflow is found, replace the PCV system with the revised PCV service parts, PCV valve YC2Z-6K773-AA, and hose, YL3Z-8A505-BA. To Install The Heated PCV Valve, Use The Following Procedure: 1. Partially drain off enough coolant into a clean, suitable container to allow hose disassembly at the top of the engine, approximately 3.8L - 7.5L (1-2 gallons) and save coolant. 2. Remove the PCV valve by disconnecting the vent hose and removing the valve from the valve cover grommet. Ensure the area is clean to prevent dirt entry into engine. 3. Install the new, heated PCV valve in the valve cover grommet. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > Customer Interest for PCV Valve Hose: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold > Page 4085 4. Disconnect the Engine Coolant Temperature (ECT) Sensor coolant supply hose from the throttle body (Figure 1). 5. Reconnect the ECT Sensor coolant supply hose to PCV valve heated fitting (use nipple that points nearly horizontal, Figure 2). 6. Install and connect the new hose from the heated PCV valve fitting (points nearly upward, Figure 2) to the throttle body fitting where the ECT Sensor coolant supply hose was disconnected. 7. Refill the system with the drained off coolant, bleed system, and check level. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > Customer Interest for PCV Valve Hose: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold > Page 4086 Parts Block OTHER APPLICABLE ARTICLES: 01-21-5 SUPERSEDES: 99-25-2 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012112A Inspect And Replace PCV 0.6 Hr. System With Updated Parts DEALER CODING CONDITION BASIC PART NO. CODE 6K773 42 OASIS CODES: 401000, 607400, 607500, 607600, 607700, 608400, 608500, 608600, 609400, 609500, 609600, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 612600, 614500, 614600, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > Customer Interest for PCV Valve Hose: > 98-21-10 > Oct > 98 > Engine - High Idle Speeds/Throttle Sticks PCV Valve Hose: Customer Interest Engine - High Idle Speeds/Throttle Sticks Article No. 98-21-10 10/26/98 IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/1/97 EQUIPPED WITH 4.6L ENGINE LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD ISSUE The vehicles identified in this TSB article should be equipped with an insulated PCV tube that was installed in production or under Recall 96S59. This insulation provides protection from PCV backflow due to ice in the PCV system created during steady speed driving in extremely cold weather. In those extreme cases where the insulated PCV tube does not completely eliminate throttle body icing due to PCV backflow, a service kit has been developed that will make these vehicles even less susceptible to PCV freezing. ACTION Verify that the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, replace the PCV hose and throttle body adapter provided with the appropriate service kit. Refer to the Instruction Sheet included in the kit for installation details. PART NUMBER PART NAME F85Z-6A603-CB Service Kit - 4.6L Romeo Engine F85Z-6A603-AB Service Kit - 4.6L Windsor Engine OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982110A Install Service kit 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 9E926 42 OASIS CODES: 404000, 610000, 610600, 612000, 612600, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PCV Valve Hose: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold PCV Valve Hose: All Technical Service Bulletins Engine - High Idle and Sticking Throttle When Cold Article No. 01-21-12 10/29/01 ^ IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES ---- VEHICLES BUILT 12/2/1997 THROUGH 7/15/1999 EQUIPPED WITH 5.4L ENGINE ^ ENGINE - 5.4L - PCV SYSTEM ICING - VEHICLES BUILT 12/2/1997 THROUGH 7/15/1999 ONLY FORD: 1998-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1999 NAVIGATOR This article is being republished in its entirety to update the Service Procedure, Service Parts and the model years involved. ISSUE In rare instances, throttle sticking may occur on a few vehicles in very cold ambient temperatures after operating at steady speed or extended idle for a period of time. This may be due to ice build-up from moisture in the Positive Crankcase Ventilation (PCV) gas on the throttle plate or throttle body. ACTION Verify the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, check for evidence of PCV system backflow. Refer to the following Service Procedure for details. SERVICE PROCEDURE Inspect the inside of the clean air tube at the PCV closure hose connection for presence of moisture, oil, or oily stains. If evidence of PCV system backflow is found, replace the PCV system with the revised PCV service parts, PCV valve YC2Z-6K773-AA, and hose, YL3Z-8A505-BA. To Install The Heated PCV Valve, Use The Following Procedure: 1. Partially drain off enough coolant into a clean, suitable container to allow hose disassembly at the top of the engine, approximately 3.8L - 7.5L (1-2 gallons) and save coolant. 2. Remove the PCV valve by disconnecting the vent hose and removing the valve from the valve cover grommet. Ensure the area is clean to prevent dirt entry into engine. 3. Install the new, heated PCV valve in the valve cover grommet. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PCV Valve Hose: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold > Page 4096 4. Disconnect the Engine Coolant Temperature (ECT) Sensor coolant supply hose from the throttle body (Figure 1). 5. Reconnect the ECT Sensor coolant supply hose to PCV valve heated fitting (use nipple that points nearly horizontal, Figure 2). 6. Install and connect the new hose from the heated PCV valve fitting (points nearly upward, Figure 2) to the throttle body fitting where the ECT Sensor coolant supply hose was disconnected. 7. Refill the system with the drained off coolant, bleed system, and check level. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PCV Valve Hose: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold > Page 4097 Parts Block OTHER APPLICABLE ARTICLES: 01-21-5 SUPERSEDES: 99-25-2 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012112A Inspect And Replace PCV 0.6 Hr. System With Updated Parts DEALER CODING CONDITION BASIC PART NO. CODE 6K773 42 OASIS CODES: 401000, 607400, 607500, 607600, 607700, 608400, 608500, 608600, 609400, 609500, 609600, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 612600, 614500, 614600, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PCV Valve Hose: > 98-21-10 > Oct > 98 > Engine - High Idle Speeds/Throttle Sticks PCV Valve Hose: All Technical Service Bulletins Engine - High Idle Speeds/Throttle Sticks Article No. 98-21-10 10/26/98 IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/1/97 EQUIPPED WITH 4.6L ENGINE LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD ISSUE The vehicles identified in this TSB article should be equipped with an insulated PCV tube that was installed in production or under Recall 96S59. This insulation provides protection from PCV backflow due to ice in the PCV system created during steady speed driving in extremely cold weather. In those extreme cases where the insulated PCV tube does not completely eliminate throttle body icing due to PCV backflow, a service kit has been developed that will make these vehicles even less susceptible to PCV freezing. ACTION Verify that the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, replace the PCV hose and throttle body adapter provided with the appropriate service kit. Refer to the Instruction Sheet included in the kit for installation details. PART NUMBER PART NAME F85Z-6A603-CB Service Kit - 4.6L Romeo Engine F85Z-6A603-AB Service Kit - 4.6L Windsor Engine OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982110A Install Service kit 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 9E926 42 OASIS CODES: 404000, 610000, 610600, 612000, 612600, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > Customer Interest for Positive Crankcase Ventilation Valve: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold Positive Crankcase Ventilation Valve: Customer Interest Engine - High Idle and Sticking Throttle When Cold Article No. 01-21-12 10/29/01 ^ IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES ---- VEHICLES BUILT 12/2/1997 THROUGH 7/15/1999 EQUIPPED WITH 5.4L ENGINE ^ ENGINE - 5.4L - PCV SYSTEM ICING - VEHICLES BUILT 12/2/1997 THROUGH 7/15/1999 ONLY FORD: 1998-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1999 NAVIGATOR This article is being republished in its entirety to update the Service Procedure, Service Parts and the model years involved. ISSUE In rare instances, throttle sticking may occur on a few vehicles in very cold ambient temperatures after operating at steady speed or extended idle for a period of time. This may be due to ice build-up from moisture in the Positive Crankcase Ventilation (PCV) gas on the throttle plate or throttle body. ACTION Verify the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, check for evidence of PCV system backflow. Refer to the following Service Procedure for details. SERVICE PROCEDURE Inspect the inside of the clean air tube at the PCV closure hose connection for presence of moisture, oil, or oily stains. If evidence of PCV system backflow is found, replace the PCV system with the revised PCV service parts, PCV valve YC2Z-6K773-AA, and hose, YL3Z-8A505-BA. To Install The Heated PCV Valve, Use The Following Procedure: 1. Partially drain off enough coolant into a clean, suitable container to allow hose disassembly at the top of the engine, approximately 3.8L - 7.5L (1-2 gallons) and save coolant. 2. Remove the PCV valve by disconnecting the vent hose and removing the valve from the valve cover grommet. Ensure the area is clean to prevent dirt entry into engine. 3. Install the new, heated PCV valve in the valve cover grommet. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > Customer Interest for Positive Crankcase Ventilation Valve: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold > Page 4110 4. Disconnect the Engine Coolant Temperature (ECT) Sensor coolant supply hose from the throttle body (Figure 1). 5. Reconnect the ECT Sensor coolant supply hose to PCV valve heated fitting (use nipple that points nearly horizontal, Figure 2). 6. Install and connect the new hose from the heated PCV valve fitting (points nearly upward, Figure 2) to the throttle body fitting where the ECT Sensor coolant supply hose was disconnected. 7. Refill the system with the drained off coolant, bleed system, and check level. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > Customer Interest for Positive Crankcase Ventilation Valve: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold > Page 4111 Parts Block OTHER APPLICABLE ARTICLES: 01-21-5 SUPERSEDES: 99-25-2 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012112A Inspect And Replace PCV 0.6 Hr. System With Updated Parts DEALER CODING CONDITION BASIC PART NO. CODE 6K773 42 OASIS CODES: 401000, 607400, 607500, 607600, 607700, 608400, 608500, 608600, 609400, 609500, 609600, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 612600, 614500, 614600, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Positive Crankcase Ventilation Valve: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold Positive Crankcase Ventilation Valve: All Technical Service Bulletins Engine - High Idle and Sticking Throttle When Cold Article No. 01-21-12 10/29/01 ^ IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES ---- VEHICLES BUILT 12/2/1997 THROUGH 7/15/1999 EQUIPPED WITH 5.4L ENGINE ^ ENGINE - 5.4L - PCV SYSTEM ICING - VEHICLES BUILT 12/2/1997 THROUGH 7/15/1999 ONLY FORD: 1998-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1999 NAVIGATOR This article is being republished in its entirety to update the Service Procedure, Service Parts and the model years involved. ISSUE In rare instances, throttle sticking may occur on a few vehicles in very cold ambient temperatures after operating at steady speed or extended idle for a period of time. This may be due to ice build-up from moisture in the Positive Crankcase Ventilation (PCV) gas on the throttle plate or throttle body. ACTION Verify the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, check for evidence of PCV system backflow. Refer to the following Service Procedure for details. SERVICE PROCEDURE Inspect the inside of the clean air tube at the PCV closure hose connection for presence of moisture, oil, or oily stains. If evidence of PCV system backflow is found, replace the PCV system with the revised PCV service parts, PCV valve YC2Z-6K773-AA, and hose, YL3Z-8A505-BA. To Install The Heated PCV Valve, Use The Following Procedure: 1. Partially drain off enough coolant into a clean, suitable container to allow hose disassembly at the top of the engine, approximately 3.8L - 7.5L (1-2 gallons) and save coolant. 2. Remove the PCV valve by disconnecting the vent hose and removing the valve from the valve cover grommet. Ensure the area is clean to prevent dirt entry into engine. 3. Install the new, heated PCV valve in the valve cover grommet. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Positive Crankcase Ventilation Valve: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold > Page 4117 4. Disconnect the Engine Coolant Temperature (ECT) Sensor coolant supply hose from the throttle body (Figure 1). 5. Reconnect the ECT Sensor coolant supply hose to PCV valve heated fitting (use nipple that points nearly horizontal, Figure 2). 6. Install and connect the new hose from the heated PCV valve fitting (points nearly upward, Figure 2) to the throttle body fitting where the ECT Sensor coolant supply hose was disconnected. 7. Refill the system with the drained off coolant, bleed system, and check level. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Positive Crankcase Ventilation Valve: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold > Page 4118 Parts Block OTHER APPLICABLE ARTICLES: 01-21-5 SUPERSEDES: 99-25-2 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012112A Inspect And Replace PCV 0.6 Hr. System With Updated Parts DEALER CODING CONDITION BASIC PART NO. CODE 6K773 42 OASIS CODES: 401000, 607400, 607500, 607600, 607700, 608400, 608500, 608600, 609400, 609500, 609600, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 612600, 614500, 614600, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications EGR Transducer Nuts ......................................................................................................................... ........................................... 2.2-5.5 Nm (22-49 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4123 Pressure Feedback Exhaust Sensor: Locations Engine View The Differential Pressure Feedback EGR Sensor is located at the right side of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4124 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the EGR transducer. 1 Remove the EGR transducer hoses. 2 Disconnect the EGR transducer electrical connector. 3 Remove the nuts. 4 Remove the EGR transducer. 4.6L engine is shown; 5.4L engine is similar INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve .................................................................................................................. .................................................. 7.75 Nm (68.6 Lb/In) Fuel Pressure Relief Valve Cap ..................... ........................................................................................................................................... 0.6 Nm (5.3 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4130 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE 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. 1. Perform the fuel pressure release procedure. 2. Remove the (A) fuel pressure relief valve with the (B) fuel pressure relief valve cap. INSTALLATION 1. Install fuel pressure relief valve. 2. Install the fuel pressure relief valve cap. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair EFI/CFI Fuel Pressure Gauge WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place the fuel in a suitable container. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 680 - 830 RPM Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accelerator Pedal: Initial Inspection and Diagnostic Overview 1. Verify the customer's concern by operating the acceleration control system to duplicate the condition. 2. Inspect to determine if any of the following mechanical concerns apply. Visual Inspection Chart Mechanical - Damaged accelerator pedal and shaft. - Damaged linkage. - Damaged accelerator cable. - High engine idle speed. - Damaged throttle body. 3. If the inspection reveals an obvious concern that can be readily identified, repair it as required. 4. If the concern remains after the inspection, determine the symptom(s) and go to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4142 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Page 4143 Accelerator Pedal: Service and Repair REMOVAL 1. Disconnect the (A) accelerator cable from the (B) accelerator pedal and shaft. 2. Remove the bolts. 3. Remove the accelerator pedal and shaft. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet engine Air Cleaner (ACL) aside. 2. Remove the (A) air cleaner element from the (B) open end of the inlet engine air cleaner. INSTALLATION 1. Install the air cleaner element. 2. Position the engine air cleaner aligning the alignment tab. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet engine air cleaner has an alignment tab which fits into a slot on the outlet engine air cleaner. This ensures a good seal and keeps unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 4148 3. Close the air cleaner clamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4157 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4158 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4164 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4165 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4166 Air Flow Meter/Sensor: Specifications Mass Air Flow Sensor Plate Nuts .................................................................................................................................................. 8-11.5 Nm (5.9-8.5 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4167 Air Flow Meter/Sensor: Locations Engine View The Mass Air Flow Sensor is located in the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4168 Air Flow Meter/Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Open the engine air cleaner. - Disconnect the MAF sensor extension harness connector from the wiring harness. - Release the air cleaner clamp. - Separate the inlet side of the engine Air Cleaner (ACL) from the outlet side of the engine air cleaner. CAUTION: Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. 3. Cut the tape on the wire loom of the extension harness. - Peel back the wire loom from the extension harness near the grommet in the engine air cleaner. 4. Remove the grommet from the outlet side of the engine air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4169 5. Remove the MAF sensor plate and Mass Air Flow sensor (MAF sensor) from the outlet side of the engine engine air cleaner. 6. Disconnect the MAF sensor electrical connector from the extension harness. 7. Separate the MAF sensor plate from the mass air flow sensor. - Remove the nuts from the MAF sensor plate. INSTALLATION CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): Customer Interest Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 4178 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 4179 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 4185 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 4186 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns Fuel: Technical Service Bulletins Fuel - Volatility Related Driveability Concerns Article No. 98-26-2 01/04/99 FUEL - INFORMATION ON GASOLINE - TIPS TO RESOLVE VOLATILITY RELATED DRIVEABILITY CONCERNS FORD: 1985-97 THUNDERBIRD 1986-99 MUSTANG, TAURUS 1987-99 ESCORT 1988-94 TEMPO 1989-97 PROBE 1990-99 CROWN VICTORIA 1992-93 FESTIVA 1995-99 CONTOUR LINCOLN-MERCURY: 1985-97 COUGAR 1986-92 MARK VII 1986-99 SABLE 1987-89 TRACER 1988-94 TOPAZ 1988-99 CONTINENTAL 1990-99 GRAND MARQUIS, TOWN CAR 1991-99 TRACER 1993-98 MARK VIII 1995-99 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1986-97 AEROSTAR 1987-96 BRONCO 1989-97 F SUPER DUTY, F-350 1989-99 F-150, F-250 LD, RANGER 1991-99 EXPLORER 1992-99 ECONOLINE 1993-99 VILLAGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1990-97 F-700 This TSB article is being republished in its entirety to expand vehicle model coverage and revise the text. ISSUE Some vehicles using winter blend fuels may exhibit a stall on start up and a no restart, hard start condition or a no start condition in unseasonably hot weather (greater than 27°C/80°F). These concerns may be related to fuel volatility from winter blend fuels during winter-spring and autumn-winter transitions and may result in a fuel pump vapor lock condition. This condition may appear to be a fuel pump failure but may be caused by winter blend fuel. ACTION Refer to the following text for further information. NOTE FUEL TANK ADDITIVES WILL NOT RESOLVE THESE CONCERNS BECAUSE VAPOR FORMS FROM CAVITATION WITHIN THE FUEL PUMP. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns > Page 4191 FILLING THE TANK TO FULL MAY BE EFFECTIVE. ADVISE CUSTOMER TO USE THE RECOMMENDED OCTANE GRADE PER OWNER MANUAL AND NOT A HIGHER GRADE. Explain to the customer that this concern may be due to a low tank level of winter blend fuel combined with unseasonably warm weather. Advise customer that filling the fuel tank to full may be effective in resolving this concern. Also, advise customer to use the recommended octane grade per their Owner Manual and not a higher grade. BACKGROUND Gasolines are seasonally adjusted, meaning they have higher volatility (vaporize easier) in the winter and lower volatility in the summer. Government mandates to improve air quality have resulted in significant changes to gasolines, such as the mandatory use of oxygenates (ethanol, methyl tertiary butyl ether (MTBE), and others) in the winter or the reduction of Reid Vapor Pressure (RVP) in the summer. The addition of oxygenates (especially ethanol) increases volatility while the reduction of RVP reduces volatility. Gasoline distribution practices often do not allow branded marketers to have much control over their gasoline's volatility other than RVP. Oxygenate (e.g., ethanol, MTBE) use is more dependent on local gasoline markets, rather than specific marketers practice. Therefore, it is difficult to recommend specific brands to avoid volatility related complaints. OTHER APPLICABLE ARTICLES: 91-8-13 SUPERSEDES: 96-5-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:402000, 404000, 602300, 603300, 607000, 607400, 608000, 608400, 609000, 609400, 610000, 611000, 611500, 612000, 614000, 614500, 623000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4200 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4201 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4202 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4203 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4204 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4210 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4211 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4212 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4213 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4214 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 EFI/CFI Fuel Pressure Gauge WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place the fuel in a suitable container. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Locations > Page 4223 Fuel Injector Wiring Harness: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 1. Disconnect the battery ground cable. 2. Remove the wiring splash shield. 3. Remove the bolt and disconnect the engine bulkhead electrical connector. 4. Disconnect the (A) fuel charging wiring electrical connector from the (B) engine control sensor wiring electrical connector. NOTE: The (A) fuel charging wiring electrical connector and the (B) engine control sensor wiring electrical connector are located behind the (C) mount. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Locations > Page 4224 5. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 6. Disconnect the Intake Manifold Tuning Valve (IMTV) electrical connector. NOTE: The Generator (GEN) is removed for clarity. 7. Disconnect the following electrical connectors: - LH ignition coil connector (A). - Camshaft Position (CMP) sensor electrical connector (B). - Radio capacitor electrical connector (C). 8. Disconnect the following electrical connectors. - RH ignition coil electrical connector (A). - Radio capacitor electrical connector (B). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Locations > Page 4225 9. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 10. Disconnect the following electrical connectors: - Idle Air Control (IAC) valve electrical connector (A). - Differential Pressure Feedback (DPFE) Exhaust Gas Recirculation (EGR) transducer electrical connector (B). - Engine Vacuum Regulator (EVR) electrical connector (C). - Throttle Position (TP) sensor electrical connector (D). 11. Disconnect the engine cooling system sensor connectors. - Disconnect the (A) Engine Coolant Temperature (ECT) sensor electrical connector. - Disconnect the (B) water temperature indicator sender unit electrical connector. 12. Disconnect the four RH fuel injector electrical connectors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Locations > Page 4226 13. Disconnect the four LH fuel injector electrical connectors. 14. Raise and support the vehicle. 15. Disconnect the A/C compressor clutch electrical connector. NOTE: The A/C compressor clutch electrical connector can be reached through the wheel well. 16. Disconnect the two Heated Oxygen Sensor (HO2S) electrical connectors. 17. Disconnect the Crankshaft Position (CKP) sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Locations > Page 4227 18. Disconnect the oil pressure sending unit electrical connector. 19. Disconnect the Electronic Variable Orifice (EVO) electrical connector. 20. Lower the vehicle. 21. Remove the fuel charging wiring. 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, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 1. Position the fuel charging wiring on the engine. 2. Raise and support the vehicle. 3. Connect the oil pressure sending unit electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Locations > Page 4228 4. Connect the EVO electrical connector. 5. Connect the CKP sensor electrical connector. 6. Connect the HO2S electrical connectors. 7. Connect the A/C compressor clutch electrical connector. 8. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Locations > Page 4229 9. Connect the LH fuel injector electrical connectors. 10. Connect the RH fuel injector electrical connectors. 11. Connect the engine cooling system sensor connections. - Connect the (A) ECT sensor electrical connector. - Connect the (B) water temperature indicator sender unit electrical connector. 12. Connect the following electrical connectors: - IAC valve electrical connector (A). - Differential Pressure Feedback EGR (DPFE) transducer electrical connector (B). - EVR electrical connector (C). - TP sensor electrical connector (D). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Locations > Page 4230 13. Connect the following electrical connections: - LH ignition coil connector (A). - CMP electrical connector (B). - Radio capacitor electrical connector (C). 14. Connect the following electrical connectors. - RH ignition coil electrical connector (A). - Radio capacitor electrical connector (B). 15. Connect the IMTV electrical connector. NOTE: The generator is removed for clarity. 16. Connect the IAT sensor electrical connectors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Locations > Page 4231 17. Connect the (A) fuel charging wiring electrical connector to the (B) engine control sensor wiring electrical connector. NOTE: The (A) fuel charging wiring electrical connector and the (B) engine control sensor wiring electrical connector are located behind the (C) mount. 18. Connect the engine bulkhead connector. 19. Install the wiring splash shield. 20. Install the accelerator control splash shield. 21. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > Customer Interest: > 98-16-12 > Aug > 98 > Fuel Rail - Fuel Leaks At Spring Lock Coupler Fuel Line Coupler: Customer Interest Fuel Rail - Fuel Leaks At Spring Lock Coupler Article No. 98-16-12 08/17/98 FUEL SYSTEM - FUEL LEAKING FROM SPRING LOCK COUPLINGS AT FUEL RAIL - AMBIENT TEMPERATURES BELOW -40 DEGREES CELSIUS (-40 DEGREES FAHRENHEIT) LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE Fuel may leak from the spring lock couplings at the fuel rail if the 0-rings have been damaged or at ambient temperatures below -40°C (-4O°F). This may be caused by the spring lock coupling 0-rings not sealing. ACTION Service replacement 0-rings are now available. Replace the spring lock coupling 0-rings. Refer to the following Service Procedure for details. SERVICE PROCEDURE Refer to the 1998 F-150/250 or Expedition/Navigator Workshop Manual, Pages 310-00-8 through 310-00-10 to disconnect the spring lock connectors and remove the 0-rings. Refer to the following to install the new 0-rings and reconnect the spring lock connectors: 1. Inspect and clean both coupling ends. 2. It female cup damage is observed such as interior scratches, replace the fuel rail. It no damage is observed to either the male or female coupling ends, replace the 0-rings being sure to observe the color coding as in Figure 1. 3. Lubricate the 0-rings with clean engine oil meeting Ford specification WSS-M2C153-F. 4. Connect the fitting. 5. Pull on the fitting to make sure it is fully engaged. 6. Install the safety clip. 7. Start the engine and check for fuel leaks. PART NUMBER PART NAME Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > Customer Interest: > 98-16-12 > Aug > 98 > Fuel Rail - Fuel Leaks At Spring Lock Coupler > Page 4240 F75Z-9J277-AA 0-Ring - Supply Side (Black, 1/2") F75Z-9J277-BA 0-Ring - Supply Side (Blue, 1/2") F75Z-9J277-DA 0-Ring - Return Side (Black, 3/8") F75Z-9J277-CA 0-Ring - Return Side (Blue, 3/8") OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981612A Replace Spring Lock 0.6 Hr. Coupling 0-Rings DEALER CODING CONDITION BASIC PART NO. CODE 9J274 42 OASIS CODES: 404000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-16-12 > Aug > 98 > Fuel Rail - Fuel Leaks At Spring Lock Coupler Fuel Line Coupler: All Technical Service Bulletins Fuel Rail - Fuel Leaks At Spring Lock Coupler Article No. 98-16-12 08/17/98 FUEL SYSTEM - FUEL LEAKING FROM SPRING LOCK COUPLINGS AT FUEL RAIL - AMBIENT TEMPERATURES BELOW -40 DEGREES CELSIUS (-40 DEGREES FAHRENHEIT) LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE Fuel may leak from the spring lock couplings at the fuel rail if the 0-rings have been damaged or at ambient temperatures below -40°C (-4O°F). This may be caused by the spring lock coupling 0-rings not sealing. ACTION Service replacement 0-rings are now available. Replace the spring lock coupling 0-rings. Refer to the following Service Procedure for details. SERVICE PROCEDURE Refer to the 1998 F-150/250 or Expedition/Navigator Workshop Manual, Pages 310-00-8 through 310-00-10 to disconnect the spring lock connectors and remove the 0-rings. Refer to the following to install the new 0-rings and reconnect the spring lock connectors: 1. Inspect and clean both coupling ends. 2. It female cup damage is observed such as interior scratches, replace the fuel rail. It no damage is observed to either the male or female coupling ends, replace the 0-rings being sure to observe the color coding as in Figure 1. 3. Lubricate the 0-rings with clean engine oil meeting Ford specification WSS-M2C153-F. 4. Connect the fitting. 5. Pull on the fitting to make sure it is fully engaged. 6. Install the safety clip. 7. Start the engine and check for fuel leaks. PART NUMBER PART NAME Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-16-12 > Aug > 98 > Fuel Rail - Fuel Leaks At Spring Lock Coupler > Page 4246 F75Z-9J277-AA 0-Ring - Supply Side (Black, 1/2") F75Z-9J277-BA 0-Ring - Supply Side (Blue, 1/2") F75Z-9J277-DA 0-Ring - Return Side (Black, 3/8") F75Z-9J277-CA 0-Ring - Return Side (Blue, 3/8") OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981612A Replace Spring Lock 0.6 Hr. Coupling 0-Rings DEALER CODING CONDITION BASIC PART NO. CODE 9J274 42 OASIS CODES: 404000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Line Coupler: > 98-15-15 > Aug > 98 > Front Suspension - Clunking Noise Stabilizer Bushing: All Technical Service Bulletins Front Suspension - Clunking Noise Article No. 98-15-15 08/03/98 ^ SUSPENSION - "CLUNKING" NOISE HEARD FROM FRONT END - VEHICLES BUILT THROUGH 4/8/98 - 4X4 ONLY ^ NOISE - "CLUNKING" HEARD FROM FRONT END - VEHICLES BUILT THROUGH 4/8/98 - 4X4 ONLY LIGHT TRUCK: 1997-98 EXPEDITION 1998 NAVIGATOR This TSB article is being republished in its entirety to clarify that this article pertains to 4X4 vehicles only. ISSUE A "clunking" noise may be heard from the front end on some vehicles. This may be caused by the front stabilizer bar contacting the frame. ACTION Replace stabilizer bar and stabilizer bar insulators with revised service parts. Refer to the 1998 Expedition/Navigator Workshop Manual, Page 204-01B-21, for details. PART NUMBER PART NAME XL1Z-5482-CA Stabilizer Bar XL1Z-5484-GA Stabilizer bar insulator (2 Required) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-10-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981515A Replace Stabilizer Bar And 1.3 Hrs. Insulators DEALER CODING CONDITION BASIC PART NO. CODE 5482 33 OASIS CODES:303000, 304000, 702000, 702100, 702300 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting Fuel Line Coupler: Service and Repair Hairpin Clip Fitting REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. Remove the shipping tab by bending it downward. 2. Spread the hairpin clip legs and push the clip into the fitting. 3. Separate the fitting from the tube. INSTALLATION 1. Inspect the fitting and the tube for damage. Remove any dirt or obstructions. 2. Apply a light coat of clean engine oil meeting Ford specification WSS-M2C153-F to the male tube end. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4259 3. Insert the hairpin clip into the fitting. 4. Align the tube and the fitting. 5. Insert the tube in the fitting and push together until a click is heard. 6. Pull on the connection to make sure it is fully engaged. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4260 Fuel Line Coupler: Service and Repair Vapor Tube Fittings REMOVAL 1. Disconnect the battery ground cable. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. 2. Disconnect the vapor tube from the fitting. 1 Squeeze the fitting. 2 Disconnect the vapor tube from the fitting. INSTALLATION 1. Inspect the fitting and the tube for damage. 2. Remove any dirt or obstructions. 3. Push the tube into the fitting until it snaps in place. 4. Pull on the connection to make sure the fitting is secure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4261 Fuel Line Coupler: Service and Repair Push Connect Fittings Fuel Line Disconnect Tool DISCONNECT WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Perform the fuel pressure release procedure. 2. Disconnect the safety clip from the male hose. 3. Install the Fuel Line Disconnect Tool and push into the fitting. 4. Separate the fittings. - Inspect for damage. - Clean the fittings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4262 CONNECT 1. Align the tube to the fitting and push it until a click is heard. NOTE: Lubricate the tube end with clean engine oil meeting Ford specification WSS-M2C153-F to ease assembly. 2. Pull on the fitting to make sure it is fully engaged, then install the safety clip. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4263 Fuel Line Coupler: Service and Repair Spring Lock Couplings Disconnect Tool (3/8 Inch) Disconnect Tool (1/2 Inch) DISCONNECT WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Perform the fuel pressure release procedure. 2. Remove the fuel tube clip. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4264 3. Install the Disconnect Tool. 4. Close and push the Disconnect Tool into the open side of the cage. 5. Separate the fitting. 6. Remove the Disconnect Tool. CONNECT 1. Follow the removal procedure in reverse order. - Inspect and clean both the coupling ends. - Lubricate the O-ring with clean engine oil meeting Ford specification WSS-M2C153-F. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications Fuel Pressure Regulator: Specifications Fuel Pressure Regulator Screws ........................................................................................................................................................ 3-4.5 Nm (26-40 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 4268 Fuel Pressure Regulator: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE 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. 1. Perform the fuel pressure release procedure. 2. Remove the fuel pressure regulator. 1 Disconnect the fuel pressure regulator vacuum hose. 2 Remove the screws. 3 Remove the fuel pressure regulator. 3. Remove and discard the two (A) fuel pressure regulator O-rings and the (B) seal. 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, RESULTING IN POSSIBLE PERSONAL INJURY. CAUTION: Use O-rings that are made if special fuel resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse O-rings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 4269 1. To install, reverse the removal procedure. NOTE: Lubricate the new seal and O-rings with engine oil. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve .................................................................................................................. .................................................. 7.75 Nm (68.6 Lb/In) Fuel Pressure Relief Valve Cap ..................... ........................................................................................................................................... 0.6 Nm (5.3 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications > Page 4273 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE 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. 1. Perform the fuel pressure release procedure. 2. Remove the (A) fuel pressure relief valve with the (B) fuel pressure relief valve cap. INSTALLATION 1. Install fuel pressure relief valve. 2. Install the fuel pressure relief valve cap. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve .................................................................................................................. .................................................. 7.75 Nm (68.6 Lb/In) Fuel Pressure Relief Valve Cap ..................... ........................................................................................................................................... 0.6 Nm (5.3 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4279 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE 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. 1. Perform the fuel pressure release procedure. 2. Remove the (A) fuel pressure relief valve with the (B) fuel pressure relief valve cap. INSTALLATION 1. Install fuel pressure relief valve. 2. Install the fuel pressure relief valve cap. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4283 Power Distribution Box The Fuel Pump Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Customer Interest for Fuel Rail: > 98-16-12 > Aug > 98 > Fuel Rail - Fuel Leaks At Spring Lock Coupler Fuel Rail: Customer Interest Fuel Rail - Fuel Leaks At Spring Lock Coupler Article No. 98-16-12 08/17/98 FUEL SYSTEM - FUEL LEAKING FROM SPRING LOCK COUPLINGS AT FUEL RAIL - AMBIENT TEMPERATURES BELOW -40 DEGREES CELSIUS (-40 DEGREES FAHRENHEIT) LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE Fuel may leak from the spring lock couplings at the fuel rail if the 0-rings have been damaged or at ambient temperatures below -40°C (-4O°F). This may be caused by the spring lock coupling 0-rings not sealing. ACTION Service replacement 0-rings are now available. Replace the spring lock coupling 0-rings. Refer to the following Service Procedure for details. SERVICE PROCEDURE Refer to the 1998 F-150/250 or Expedition/Navigator Workshop Manual, Pages 310-00-8 through 310-00-10 to disconnect the spring lock connectors and remove the 0-rings. Refer to the following to install the new 0-rings and reconnect the spring lock connectors: 1. Inspect and clean both coupling ends. 2. It female cup damage is observed such as interior scratches, replace the fuel rail. It no damage is observed to either the male or female coupling ends, replace the 0-rings being sure to observe the color coding as in Figure 1. 3. Lubricate the 0-rings with clean engine oil meeting Ford specification WSS-M2C153-F. 4. Connect the fitting. 5. Pull on the fitting to make sure it is fully engaged. 6. Install the safety clip. 7. Start the engine and check for fuel leaks. PART NUMBER PART NAME Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Customer Interest for Fuel Rail: > 98-16-12 > Aug > 98 > Fuel Rail - Fuel Leaks At Spring Lock Coupler > Page 4292 F75Z-9J277-AA 0-Ring - Supply Side (Black, 1/2") F75Z-9J277-BA 0-Ring - Supply Side (Blue, 1/2") F75Z-9J277-DA 0-Ring - Return Side (Black, 3/8") F75Z-9J277-CA 0-Ring - Return Side (Blue, 3/8") OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981612A Replace Spring Lock 0.6 Hr. Coupling 0-Rings DEALER CODING CONDITION BASIC PART NO. CODE 9J274 42 OASIS CODES: 404000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 98-16-12 > Aug > 98 > Fuel Rail - Fuel Leaks At Spring Lock Coupler Fuel Rail: All Technical Service Bulletins Fuel Rail - Fuel Leaks At Spring Lock Coupler Article No. 98-16-12 08/17/98 FUEL SYSTEM - FUEL LEAKING FROM SPRING LOCK COUPLINGS AT FUEL RAIL - AMBIENT TEMPERATURES BELOW -40 DEGREES CELSIUS (-40 DEGREES FAHRENHEIT) LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE Fuel may leak from the spring lock couplings at the fuel rail if the 0-rings have been damaged or at ambient temperatures below -40°C (-4O°F). This may be caused by the spring lock coupling 0-rings not sealing. ACTION Service replacement 0-rings are now available. Replace the spring lock coupling 0-rings. Refer to the following Service Procedure for details. SERVICE PROCEDURE Refer to the 1998 F-150/250 or Expedition/Navigator Workshop Manual, Pages 310-00-8 through 310-00-10 to disconnect the spring lock connectors and remove the 0-rings. Refer to the following to install the new 0-rings and reconnect the spring lock connectors: 1. Inspect and clean both coupling ends. 2. It female cup damage is observed such as interior scratches, replace the fuel rail. It no damage is observed to either the male or female coupling ends, replace the 0-rings being sure to observe the color coding as in Figure 1. 3. Lubricate the 0-rings with clean engine oil meeting Ford specification WSS-M2C153-F. 4. Connect the fitting. 5. Pull on the fitting to make sure it is fully engaged. 6. Install the safety clip. 7. Start the engine and check for fuel leaks. PART NUMBER PART NAME Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 98-16-12 > Aug > 98 > Fuel Rail - Fuel Leaks At Spring Lock Coupler > Page 4298 F75Z-9J277-AA 0-Ring - Supply Side (Black, 1/2") F75Z-9J277-BA 0-Ring - Supply Side (Blue, 1/2") F75Z-9J277-DA 0-Ring - Return Side (Black, 3/8") F75Z-9J277-CA 0-Ring - Return Side (Blue, 3/8") OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981612A Replace Spring Lock 0.6 Hr. Coupling 0-Rings DEALER CODING CONDITION BASIC PART NO. CODE 9J274 42 OASIS CODES: 404000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4299 Fuel Rail: Specifications Fuel Injection Supply Manifold Bolts .............................................................................................................................................. 8-11 Nm (71-102 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4300 Fuel Rail: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE 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. 1. Disconnect the battery ground cable. 2. Perform the fuel pressure release procedure. 3. Partially drain the cooling system. 4. Remove the power steering fluid reservoir bracket. 1 Remove the bolts. 2 Position the power steering fluid reservoir bracket out of the way. 5. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 6. Disconnect the fuel pressure regulator valve vacuum hose. CAUTION: After disconnecting, plug the fuel lines to prevent leakage. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4301 7. Disconnect the two fuel lines. 8. Disconnect the RH fuel injector electrical connectors. 9. Disconnect the LH fuel injector electrical connectors. 10. Disconnect the heater water inlet tube hose. 1 Release and move the hose clamp. 2 Disconnect the heater water inlet tube hose and position aside. 11. Remove the brake booster bracket and tube. 1 Remove the nut. 2 Release and move the two hose clamps. 3 Remove the brake booster tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4302 12. Remove the Positive Crankcase Ventilation (PCV) hose. 13. Disconnect the Exhaust Gas Recirculation (EGR) connections. - Two Differential Pressure Feedback (DPFE) transducer hoses (B). - EGR valve to exhaust manifold tube upper fitting (A). - EGR valve to exhaust manifold tube lower fitting and remove the EGR exhaust tube (C). 14. Disconnect the EGR valve vacuum hose. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4303 15. Disconnect the Vapor Management Valve (VMV) hose. 16. Remove the fuel injection supply manifold bolts and lift fuel injection supply manifold and injectors upward out of intake manifold. 17. Remove the (A) fuel injectors from the (B) fuel injection supply manifold. 18. Replace the O-rings from each fuel injector, if necessary. 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, RESULTING IN POSSIBLE PERSONAL INJURY. CAUTION: Use replacement O-rings if necessary. 1. Install two O-rings onto each fuel injector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4304 NOTE: Lubricate new O-rings with engine oil. 2. Install fuel injectors into intake manifold. 3. Install fuel injectors into the fuel fuel injection supply manifold. 4. Install the bolts. 5. Connect the vapor management valve hose. 6. Connect the EGR valve vacuum hose. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4305 7. Connect the EGR connections: - Two DPFE transducer hoses (A). - EGR valve to exhaust manifold tube upper fitting (B). - EGR valve to exhaust manifold tube lower fitting (C). 8. Install the PCV hose. 9. Install the brake booster bracket and tube. 1 Install the brake booster tube. 2 Install the two hose clamps 3 Install the nut. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4306 10. Connect the heater water inlet tube. 1 Connect the heater inlet tube hose to inlet tube. 2 Slide clamp into position. 11. Connect the LH fuel injector electrical Connectors. 12. Connect the RH fuel injector electrical connectors. 13. Connect the two fuel lines. 14. Connect the fuel pressure regulator valve vacuum hose. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4307 15. Install the accelerator control splash shield. 16. Install the power steering oil reservoir bracket. 17. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4317 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4318 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4319 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4320 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4321 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4327 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4328 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4329 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4330 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4331 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4332 Fuel Filler Hose: Specifications Fuel Tank Filler Pipe Bolts ......................................................................................................................................................... 1.6-2.2 Nm (14.2-19 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4333 Fuel Filler Hose: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove fuel tank filler cap. 2. Remove the screws. 3. Loosen the hose clamp and disconnect the fuel filler vent hose from the fuel tank filler pipe. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4334 4. Disconnect the fuel tank to filler pipe hose and remove the fuel tank filler pipe. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4343 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4344 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4345 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4346 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4347 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4353 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4354 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4355 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4356 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4357 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications Idle Air Control (IAC) Valve Bolts .......................................................................................................................................... 3.1-4.3 Nm (27.6-38.3 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 4361 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 3. Remove IAC valve. 1 Disconnect the electrical connector. 2 Disconnect the throttle bypass hose. 3 Remove the bolts. 4 Remove the Idle Air Control valve (IAC valve). 5 Remove and discard the idle air control gasket. INSTALLATION 1. Position the idle air control valve and a new idle air control gasket and tighten the bolts in 2 steps. - Step 1: 3-10 Nm (71-89 lb/in) - Step 2: Rotate 90 degrees Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 4362 2. Connect the IAC electrical connector. 3. Connect the throttle bypass hose. 4. Connect the battery ground cable. 5. Install the accelerator control splash shield. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications Inertia Fuel Shutoff Switch: Specifications Inertia Fuel Shutoff Switch Bolts ................................................................................................................................................... 1.6-2.2 Nm (15-19 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 4366 Inertia Fuel Shutoff Switch: Locations The inertia fuel shutoff switch is located in the right kick panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 4367 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. The IFS 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 4368 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the RH cowl side trim panel. 3. Disconnect the inertia fuel shutoff switch electrical connector. 4. Remove the inertia fuel shutoff switch. 1 Remove the bolts. 2 Remove the inertia fuel shutoff switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair Intake Air Duct: Service and Repair REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) positive crankcase ventilation hose and the (B) idle air control valve inlet tube. 4. Loosen the screws and remove the air cleaner outlet tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Page 4372 INSTALLATION 1. Follow the removal procedure in reverse order. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4376 Power Distribution Box The Powertrain Control Module Power Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 4381 Power Distribution Box The Fuel Pump Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Main Relay (Computer/Fuel System): Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 4385 Power Distribution Box The Powertrain Control Module Power Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4395 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4396 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4402 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4403 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4404 Air Flow Meter/Sensor: Specifications Mass Air Flow Sensor Plate Nuts .................................................................................................................................................. 8-11.5 Nm (5.9-8.5 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4405 Air Flow Meter/Sensor: Locations Engine View The Mass Air Flow Sensor is located in the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4406 Air Flow Meter/Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Open the engine air cleaner. - Disconnect the MAF sensor extension harness connector from the wiring harness. - Release the air cleaner clamp. - Separate the inlet side of the engine Air Cleaner (ACL) from the outlet side of the engine air cleaner. CAUTION: Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. 3. Cut the tape on the wire loom of the extension harness. - Peel back the wire loom from the extension harness near the grommet in the engine air cleaner. 4. Remove the grommet from the outlet side of the engine air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4407 5. Remove the MAF sensor plate and Mass Air Flow sensor (MAF sensor) from the outlet side of the engine engine air cleaner. 6. Disconnect the MAF sensor electrical connector from the extension harness. 7. Separate the MAF sensor plate from the mass air flow sensor. - Remove the nuts from the MAF sensor plate. INSTALLATION CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications Inertia Fuel Shutoff Switch: Specifications Inertia Fuel Shutoff Switch Bolts ................................................................................................................................................... 1.6-2.2 Nm (15-19 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 4411 Inertia Fuel Shutoff Switch: Locations The inertia fuel shutoff switch is located in the right kick panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 4412 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. The IFS 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 4413 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the RH cowl side trim panel. 3. Disconnect the inertia fuel shutoff switch electrical connector. 4. Remove the inertia fuel shutoff switch. 1 Remove the bolts. 2 Remove the inertia fuel shutoff switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position (TP) Sensor Bolts ............................................................................................................................................... 2.8-3.4 Nm (25-30 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4417 Throttle Position Sensor: Locations Engine View The Throttle Position Sensor is attached to the throttle body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4418 Throttle Position Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the splash shield. 3. Remove the Throttle Position sensor (TP sensor). 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the throttle position sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4419 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 02-19-3 > Sep > 02 > Emissions - High Idle Speeds/Throttle Sticking Throttle Body: Customer Interest Emissions - High Idle Speeds/Throttle Sticking Article No. 02-19-3 09/30/02 ^ DRIVEABILITY - IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/31/01 EQUIPPED WITH 4.6L ENGINE ^ 4.6L - IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/31/01 EQUIPPED WITH 4.6L ENGINE FORD: 1997-1999 F-250 LD 1997-2002 EXPEDITION, F-150 ISSUE In rare instances, throttle sticking may occur on a few vehicles in very cold ambient temperatures after operating at steady speed or extended idle for a period of time. This may be due to ice build-up from moisture in the PCV gas on the throttle plate or throttle body. ACTION Verify the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, check for evidence of PCV system backflow. Refer to the following Service Procedure for details. SERVICE PROCEDURE Inspect the inside of the clean air tube at the PCV closure hose connection for presence of moisture, oil, or oily stains. If evidence of PCV system backflow is found, replace the PCV system with the PCV Service Kit 1L3Z-6A603-AA. Refer to the Instruction Sheet within the PCV Service Kit for Service Procedure. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 021903A Replace PCV System with 1.5 Hrs. PCV Service Kit: 1997-2002 F-150, Expedition 1997-1999 F-250 LD DEALER CODING CONDITION BASIC PART NO. CODE 6C324 42 OASIS CODES: 401000, 402000, 404000, 499000, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 98-21-10 > Oct > 98 > Engine - High Idle Speeds/Throttle Sticks Throttle Body: Customer Interest Engine - High Idle Speeds/Throttle Sticks Article No. 98-21-10 10/26/98 IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/1/97 EQUIPPED WITH 4.6L ENGINE LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD ISSUE The vehicles identified in this TSB article should be equipped with an insulated PCV tube that was installed in production or under Recall 96S59. This insulation provides protection from PCV backflow due to ice in the PCV system created during steady speed driving in extremely cold weather. In those extreme cases where the insulated PCV tube does not completely eliminate throttle body icing due to PCV backflow, a service kit has been developed that will make these vehicles even less susceptible to PCV freezing. ACTION Verify that the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, replace the PCV hose and throttle body adapter provided with the appropriate service kit. Refer to the Instruction Sheet included in the kit for installation details. PART NUMBER PART NAME F85Z-6A603-CB Service Kit - 4.6L Romeo Engine F85Z-6A603-AB Service Kit - 4.6L Windsor Engine OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982110A Install Service kit 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 9E926 42 OASIS CODES: 404000, 610000, 610600, 612000, 612600, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 02-19-3 > Sep > 02 > Emissions - High Idle Speeds/Throttle Sticking Throttle Body: All Technical Service Bulletins Emissions - High Idle Speeds/Throttle Sticking Article No. 02-19-3 09/30/02 ^ DRIVEABILITY - IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/31/01 EQUIPPED WITH 4.6L ENGINE ^ 4.6L - IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/31/01 EQUIPPED WITH 4.6L ENGINE FORD: 1997-1999 F-250 LD 1997-2002 EXPEDITION, F-150 ISSUE In rare instances, throttle sticking may occur on a few vehicles in very cold ambient temperatures after operating at steady speed or extended idle for a period of time. This may be due to ice build-up from moisture in the PCV gas on the throttle plate or throttle body. ACTION Verify the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, check for evidence of PCV system backflow. Refer to the following Service Procedure for details. SERVICE PROCEDURE Inspect the inside of the clean air tube at the PCV closure hose connection for presence of moisture, oil, or oily stains. If evidence of PCV system backflow is found, replace the PCV system with the PCV Service Kit 1L3Z-6A603-AA. Refer to the Instruction Sheet within the PCV Service Kit for Service Procedure. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 021903A Replace PCV System with 1.5 Hrs. PCV Service Kit: 1997-2002 F-150, Expedition 1997-1999 F-250 LD DEALER CODING CONDITION BASIC PART NO. CODE 6C324 42 OASIS CODES: 401000, 402000, 404000, 499000, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 98-21-10 > Oct > 98 > Engine - High Idle Speeds/Throttle Sticks Throttle Body: All Technical Service Bulletins Engine - High Idle Speeds/Throttle Sticks Article No. 98-21-10 10/26/98 IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/1/97 EQUIPPED WITH 4.6L ENGINE LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD ISSUE The vehicles identified in this TSB article should be equipped with an insulated PCV tube that was installed in production or under Recall 96S59. This insulation provides protection from PCV backflow due to ice in the PCV system created during steady speed driving in extremely cold weather. In those extreme cases where the insulated PCV tube does not completely eliminate throttle body icing due to PCV backflow, a service kit has been developed that will make these vehicles even less susceptible to PCV freezing. ACTION Verify that the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, replace the PCV hose and throttle body adapter provided with the appropriate service kit. Refer to the Instruction Sheet included in the kit for installation details. PART NUMBER PART NAME F85Z-6A603-CB Service Kit - 4.6L Romeo Engine F85Z-6A603-AB Service Kit - 4.6L Windsor Engine OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982110A Install Service kit 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 9E926 42 OASIS CODES: 404000, 610000, 610600, 612000, 612600, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 4441 Throttle Body: Specifications Throttle Body Bolts .............................................................................................................................. .............................................. 8-10 Nm (71-89 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 4442 Throttle Body: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. CAUTION: Throttle body bore and plate area have a special coating and cannot be cleaned. 1. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 2. Remove the air cleaner outlet tube from the throttle body. 3. Disconnect the Throttle Position (TP) sensor electrical connector. 4. Disconnect the (A) accelerator cable and (B) speed control actuator cable. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 4443 5. Remove the throttle body. 1 Remove the bolts. 2 Remove the (A) throttle body and the (B) throttle body gasket. NOTE: Discard the old gasket. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications Throttle Cable/Linkage: Specifications Accelerator Pedal and Shaft Bolts .............................................................................................................................................. 23.3-31.7 Nm (17-23 Lb/Ft) Accelerator Cable to Dash Panel Bolts .......................................................................................................................................... 2.3-3.3 Nm (20-29 Lb/In) Accelerator Control Splash Shield Bolts ........................................................................................................................................ 5.2-7.2 Nm (46-64 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 4447 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Throttle Cable/Linkage: Initial Inspection and Diagnostic Overview 1. Verify the customer's concern by operating the acceleration control system to duplicate the condition. 2. Inspect to determine if any of the following mechanical concerns apply. Visual Inspection Chart Mechanical - Damaged accelerator pedal and shaft. - Damaged linkage. - Damaged accelerator cable. - High engine idle speed. - Damaged throttle body. 3. If the inspection reveals an obvious concern that can be readily identified, repair it as required. 4. If the concern remains after the inspection, determine the symptom(s) and go to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4450 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Page 4451 Throttle Cable/Linkage: Service and Repair REMOVAL 1. Disconnect the (A) accelerator cable from the (B) accelerator pedal and shaft. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 3. Remove the accelerator cable clip. 4. Remove the (A) bolts and pull the (B) accelerator cable through the dash panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Page 4452 5. Remove the fitting and the accelerator cable from the accelerator cable bracket. 6. Disconnect the accelerator cable from the throttle body cam. 1 Roll the throttle body cam forward. 2 Slide the accelerator cable end from the throttle body cam. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position (TP) Sensor Bolts ............................................................................................................................................... 2.8-3.4 Nm (25-30 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4456 Throttle Position Sensor: Locations Engine View The Throttle Position Sensor is attached to the throttle body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4457 Throttle Position Sensor: Service and Repair REMOVAL CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the splash shield. 3. Remove the Throttle Position sensor (TP sensor). 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the throttle position sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4458 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Page 4463 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Page 4464 Firing Order 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order Firing Order: 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt ......................................................................................................................................................... 8-12 Nm (71-106 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4472 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located in front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4473 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 4.6L shown, 5.4L similar 2. Remove the Camshaft Position sensor (CMP sensor). 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Engine View The Crankshaft Position Sensor is located at the lower front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4477 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the accessory drive belt. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Disconnect the Crankshaft Position (CKP) electrical connector. 4. Disconnect the A/C compressor. 1 Remove the bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the (CKP) sensor bolt and the crankshaft position sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4478 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair REMOVAL CAUTION: Spark plug wires must be connected to the proper ignition coil terminal and spark plug. Mark the spark plug wire locations. 1. Grasp the spark plug boot firmly and use a twisting, pulling motion to disconnect the spark plug wires from the spark plugs. 2. Squeeze the locking tabs and disconnect the spark plug wire from the ignition coil. INSTALLATION 1. Apply Silicone Brake Caliper Grease Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire boots. 2. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4486 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4487 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4488 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4489 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4490 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4491 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 4492 Ignition Coil: Specifications Ignition Coil and Bracket Bolts, LH and RH ................................................................................................................................... 20-30 Nm (15-22 Lb/Ft) Ignition Coil and Bracket Nut, LH ................................................................................................................................................... 20-30 Nm (15-22 Lb/Ft) Ignition Coil Bolts .................................................................................................... ............................................................................ 5-7 Nm (44-62 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Connector Views Ignition Coil: Connector Views Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Connector Views > Page 4495 Ignition Coil: Mechanical Diagrams The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Connector Views > Page 4496 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Connector Views > Page 4497 Firing Order 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4498 Ignition Coil: Description and Operation NOTE: The following image is a generic image and may not apply to your vehicle. PURPOSE The Electronic Ignition-High Data Rate System (EI) coils provide high voltage needed to jump the gap of the spark plugs and ignite the air/fuel mixture. CONSTRUCTION The coil pack contains multiple coils. Each coil within a coil pack contains a primary and secondary circuit. Primary Windings The windings in the primary circuit is wound on a silicon steel core bobbin. The primary circuit grounds use the same ground through the DIS module. Secondary Windings The winding in the secondary circuit is on a segmented bobbin. The secondary winding uses smaller gauge wire and more turns than the primary circuit. The secondary high tension towers are connected in pairs. OPERATION The ignition coil fires two spark plugs simultaneously, one on the compression stroke and one on the exhaust stroke. Effective Spark When a piston is on compression stroke, most of the ignition coil's available current jumps the gap of the spark plug firing from the center electrode to side electrode, because the resistance is low. Wasted Spark When the companion piston is on exhaust stroke, the spark is wasted. Very little coil energy is wasted. The companion plug fires from the side electrode to the center electrode. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4499 Ignition Coil: Service and Repair REMOVAL NOTE: Procedure is for either RH or LH ignition coil; RH ignition coil is shown. 1. Disconnect the ignition coil electrical connections. 1 Disconnect the ignition coil electrical connector. 2 Disconnect the radio capacitor electrical connector. 2. Squeeze the (A) locking tabs and disconnect the (B) spark plug wires. CAUTION: Spark plug wires must be connected to the proper ignition coil terminal. Mark spark plug wire locations. 3. Remove the ignition coil. 1 Remove the bolts. 2 Remove the ignition Coil. 4. Inspect the ignition coil for carbon tracks or damage, replace as necessary. INSTALLATION NOTE: Procedure is for either LH or RH ignition coil RH is shown. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4500 1. Install the ignition coil. 1 Position the ignition coil. 2 Install the bolts. 2. Connect the ignition coil electrical connections. 1 Connect the ignition coil electrical connector. 2 Connect the radio capacitor electrical connector. 3. Squeeze the locking tabs and connect the spark plug wires. CAUTION: Spark plug wires must be connected to the proper ignition coil terminal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations The ignition control module is integrated within the powertrain control module. It is not a separately replaceable component. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 4504 Ignition Control Module: Description and Operation PURPOSE - The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM). The ICM receives engine position and speed information from within the crankshaft position sensor and desired spark advance information from the PCM. OPERATION - The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use within The PCM. - The PCM uses this information to determine which ignition coil to fire, calculating the turn ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor (KS) .............................................................................................................................. ............................................. 15-20 Nm (11-15 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 4508 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Knock Sensor (KS). 1 Disconnect the electrical connector. 2 Remove the knock sensor. INSTALLATION 1. Install the knock sensor. 1 Install the knock sensor. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations The ignition control module is integrated within the powertrain control module. It is not a separately replaceable component. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 4513 Ignition Control Module: Description and Operation PURPOSE - The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM). The ICM receives engine position and speed information from within the crankshaft position sensor and desired spark advance information from the PCM. OPERATION - The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use within The PCM. - The PCM uses this information to determine which ignition coil to fire, calculating the turn ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt ......................................................................................................................................................... 8-12 Nm (71-106 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4518 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located in front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4519 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Always disconnect the battery ground cable prior to work on the electronic engine controls or damage to the electronic component may occur. 4.6L shown, 5.4L similar 2. Remove the Camshaft Position sensor (CMP sensor). 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Engine View The Crankshaft Position Sensor is located at the lower front of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4523 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the accessory drive belt. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Disconnect the Crankshaft Position (CKP) electrical connector. 4. Disconnect the A/C compressor. 1 Remove the bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the (CKP) sensor bolt and the crankshaft position sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4524 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4530 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4531 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4532 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4533 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4534 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4535 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key and turn to the RUN position. (2) Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 4538 Ignition Switch Lock Cylinder: Service and Repair Non-Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 4539 - Thoroughly clean all drill shavings from the steering column and inspect for damage. INSTALLATION 1. To install, reverse the removal procedure, using a new ignition switch lock cylinder. - Verify ignition switch lock cylinder operation. NOTE: - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. - Use a new ignition switch lock cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor (KS) .............................................................................................................................. ............................................. 15-20 Nm (11-15 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 4543 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Knock Sensor (KS). 1 Disconnect the electrical connector. 2 Remove the knock sensor. INSTALLATION 1. Install the knock sensor. 1 Install the knock sensor. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark Plug Torque ............................................................................................................................... ............................................. 9-20 Nm (80-178 Lb/In) Spark Plug Gap ............................................... ....................................................................................................................... 1.32-1.42 mm (0.052-0.056 in) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap > Page 4548 Spark Plug: Specifications Torque Spark Plug Torque ............................................................................................................................... ............................................. 9-20 Nm (80-178 Lb/In) Spark Plug Gap ............................................... ....................................................................................................................... 1.32-1.42 mm (0.052-0.056 in) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4549 Spark Plug: Application and ID RH Original Spark Plug ....................................................................................................................... ........................................................ AWSF32PG (a) LH Original Spark Plug ..................................... ............................................................................................................................................. AWSF32P (a) Replacement Spark Plug (Either Side) ......................................................................................................................................................... AWSF32PP (a) (a) If a spark plug is removed for examination, it must be reinstalled in the same cylinder. If a new spark plug needs to be installed, use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4550 Spark Plug: Service and Repair REMOVAL CAUTION: Spark plug wires must be connected to the proper ignition coil terminal and spark plug. Mark the spark plug wire locations. NOTE: Use compressed air to remove any debris from the spark plug well before removing the spark plugs. 1. Grasp the spark plug boot firmly and use a twisting, pulling motion to disconnect the spark plug wires from the spark plugs. 2. Remove the spark plugs. NOTE: Remove any foreign debris from the spark plug wells with compressed air. 3. Inspect the spark plug. INSTALLATION 1. Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire boots. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4551 2. Adjust the spark plug gap as required. 3. Install the spark plugs. 4. Connect the spark plug wires. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Description and Operation Pressure Regulating Solenoid: Description and Operation ELECTRONIC PRESSURE CONTROL (EPC) SOLENOID The Electronic Pressure Control (EPC) solenoid regulates transmission pressure. EPC valve pressure is used to control line pressure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Description and Operation > Page 4558 Pressure Regulating Solenoid: Service and Repair REMOVAL 1. Remove the manual control lever. 2. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on locking tabs to disconnect the sensors. Disconnect the molded lead frame from the sensors. 1 Disconnect the shift solenoid SSA/SS1 and SSB/SS2. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter connector. 3. Remove the EPC solenoid. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Description and Operation > Page 4559 1. Install the EPC solenoid. 2. Connect the molded lead frame to the sensors. - Connect the bulkhead inter connector. - Connect the Electronic Pressure Control (EPC) solenoid. - Connect the Torque Converter Clutch (TCC). - Connect the shift solenoid SSA/SS1 and SSB/SS2. 3. Install the manual control lever. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications TORQUE SPECIFICATIONS Brake Shift Interlock Solenoid Bolts ........................................................................................................................................ 7-11 Nm (63-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4563 Shift Interlock Solenoid: Service and Repair REMOVAL 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation Shift Solenoid: Description and Operation Part 1 Of 2 Part 2 Of 2 SHIFT SOLENOID-SSA/SS1 AND SSB/SS2 Two on/off shift solenoids provide gear selection of first through fourth gears by controlling the pressure to the three shift valves. One unit containing the two shift solenoids is located in the main control valve body. The shift solenoids are two-way normally open style. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TORQUE SPECIFICATIONS TCC Solenoid Bolt ............................................................................................................................... .................................. 9-11 Nm (80-100 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 4570 Torque Converter Clutch Solenoid: Description and Operation Part 1 Of 2 Part 2 Of 2 The Torque Converter Clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications TORQUE SPECIFICATIONS Shift Motor Bolts .................................................................................................................................. .................................... 8-11 Nm (71-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4575 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4576 Transfer Case Actuator: Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4577 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4578 Transfer Case Actuator: Description and Operation The shifting operation of the front drive axle is accomplished by activating the vacuum motor from a switch located on the instrument panel. It is recommended that shifting of the front axle should be done with the front wheels in a straight ahead position and during light throttle application. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor Transfer Case Actuator: Service and Repair Transfer Case Shift Motor REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the transfer case shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use proper electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 4581 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the four bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the electric shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 4582 Transfer Case Actuator: Service and Repair Vacuum Reservoir REMOVAL 1. Remove the right front fender splash shield. 1 Remove the screws. 2 Remove the pushpins. 3 Remove the right front fender splash shield. 2. Remove the engine vacuum reservoir. 1 Remove the bolts. 2 Disconnect the vacuum harness from the engine vacuum reservoir and remove the engine vacuum reservoir. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 4583 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 4584 Transfer Case Actuator: Service and Repair Auxiliary Vacuum Reservoir REMOVAL 1. Remove the front fender splash shield. 2. Disconnect the vacuum harness from the auxiliary vacuum reservoir and the A/C vacuum reservoir. 3. Slide the vacuum reservoir assembly out of the battery tray. 4. Separate the A/C vacuum reservoir from the auxiliary vacuum reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) AND TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The Transmission Control Switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the Transmission Control Indicator Lamp (TCIL) when the switch is off. The TCIL indicates overdrive cancel mode activated (lamp on) and Electronic Pressure Control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Overdrive Indicator Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the transmission external control. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart: 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4592 Overdrive Indicator Lamp: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4593 Overdrive Indicator Lamp: Pinpoint Tests Test D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4594 Test D1 - D2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4595 Test D3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the (D) position. - Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise ((D) position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumb wheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay Instrument Panel View The Torque On Demand Relay is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 4612 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay Instrument Panel View The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay Torque On Demand Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay > Page 4615 Transfer Case Shift Relays Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission > Page 4622 Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Page 4623 Overdrive Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) AND TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The Transmission Control Switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the Transmission Control Indicator Lamp (TCIL) when the switch is off. The TCIL indicates overdrive cancel mode activated (lamp on) and Electronic Pressure Control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Testing and Inspection > Initial Inspection and Diagnostic Overview Overdrive Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the transmission external control. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart: 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4626 Overdrive Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4627 Overdrive Switch: Pinpoint Tests Test C1 - C2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4628 Test C2 - C3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4629 Test C3 - C4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4630 Test C4 - C5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Testing and Inspection > Page 4631 Overdrive Switch: Service and Repair REMOVAL 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS Transmission Range (TR) Sensor Bolts .................................................................................................................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 4635 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at the left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 4636 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 4637 Transmission Position Switch/Sensor: Description and Operation DIGITAL TRANSMISSION RANGE (TR) SENSOR The Digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in Park and Neutral, the back-up lamp circuit in Reverse and the neutral sense circuit (4x4 only) in Neutral. The digital TR sensor also opens and closes a set of four switches that are monitored by the powertrain control module to determine the position of the manual lever (P,R,N,D,2,1). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 4638 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Disconnect the digital TR electrical connector. 6. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 7. Loosen the digital TR bolts. 8. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 4639 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. 9. Tighten the bolts. 10. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 11. With the manual lever in overdrive connect the shift lever control cable. 12. Install the digital TR sensor electrical connector. 13. Lower the vehicle. 14. Connect the battery ground cable. 15. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Transmission Speed Sensor: Locations Transmission View The Output Shaft Speed Sensor is located at the left side of the transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Page 4643 Output Shaft Speed Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Page 4644 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED (OSS) SENSOR The Output Shaft Speed (OSS) sensor is a magnetic pickup, located at the output shaft ring gear, that sends a signal to the Powertrain Control Module (PCM) to indicate transmission output shaft speed. The OSS is used for torque converter clutch control, shift scheduling and to determine electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Temperature Sensor, Transmission Control Transmission Temperature Sensor/Switch: Description and Operation Temperature Sensor, Transmission Control TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR The Transmission Fluid Temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermister. It sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits Torque Converter Clutch (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Temperature Sensor, Transmission Control > Page 4649 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor/Switch, A/T TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR The Transmission Fluid Temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermister. It sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits Torque Converter Clutch (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications Gear Sensor/Switch: Specifications TORQUE SPECIFICATIONS Shift Range Selector Switch Screws ........................................................................................................................................... 2-3 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications > Page 4657 Gear Sensor/Switch: Service and Repair REMOVAL 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the shift range selector switch knob. 2 Disconnect the shift range selector switch electrical connector. 3 Remove the two shift range selector switch bolts. 4 Remove the shift range selector switch. INSTALLATION 1. Install the shift range selector switch. 1 Position the shift range selector switch. 2 Install the bolts. 3 Install the electrical connector. 4 Install the knob. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications > Page 4658 2. Install the center instrument panel trim panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Speed Sensor Bolt ........................................................................................................................................................... 3-6 Nm (27-53 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns PROM - Programmable Read Only Memory: Customer Interest PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4670 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4671 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4672 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 (V8-281 4.6L SOHC (1998)) 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 4678 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 (V8-281 4.6L SOHC (1998)) 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 4679 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 (V8-281 4.6L SOHC (1998)) 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: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4684 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4685 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4686 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 (V8-281 4.6L SOHC (1998)) 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 4692 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 (V8-281 4.6L SOHC (1998)) 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 4693 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation Pressure Regulating Solenoid: Description and Operation ELECTRONIC PRESSURE CONTROL (EPC) SOLENOID The Electronic Pressure Control (EPC) solenoid regulates transmission pressure. EPC valve pressure is used to control line pressure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 4700 Pressure Regulating Solenoid: Service and Repair REMOVAL 1. Remove the manual control lever. 2. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on locking tabs to disconnect the sensors. Disconnect the molded lead frame from the sensors. 1 Disconnect the shift solenoid SSA/SS1 and SSB/SS2. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter connector. 3. Remove the EPC solenoid. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 4701 1. Install the EPC solenoid. 2. Connect the molded lead frame to the sensors. - Connect the bulkhead inter connector. - Connect the Electronic Pressure Control (EPC) solenoid. - Connect the Torque Converter Clutch (TCC). - Connect the shift solenoid SSA/SS1 and SSB/SS2. 3. Install the manual control lever. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications TORQUE SPECIFICATIONS Brake Shift Interlock Solenoid Bolts ........................................................................................................................................ 7-11 Nm (63-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4705 Shift Interlock Solenoid: Service and Repair REMOVAL 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation Shift Solenoid: Description and Operation Part 1 Of 2 Part 2 Of 2 SHIFT SOLENOID-SSA/SS1 AND SSB/SS2 Two on/off shift solenoids provide gear selection of first through fourth gears by controlling the pressure to the three shift valves. One unit containing the two shift solenoids is located in the main control valve body. The shift solenoids are two-way normally open style. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TORQUE SPECIFICATIONS TCC Solenoid Bolt ............................................................................................................................... .................................. 9-11 Nm (80-100 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 4712 Torque Converter Clutch Solenoid: Description and Operation Part 1 Of 2 Part 2 Of 2 The Torque Converter Clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications TORQUE SPECIFICATIONS Shift Motor Bolts .................................................................................................................................. .................................... 8-11 Nm (71-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4717 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4718 Transfer Case Actuator: Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4719 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4720 Transfer Case Actuator: Description and Operation The shifting operation of the front drive axle is accomplished by activating the vacuum motor from a switch located on the instrument panel. It is recommended that shifting of the front axle should be done with the front wheels in a straight ahead position and during light throttle application. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor Transfer Case Actuator: Service and Repair Transfer Case Shift Motor REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the transfer case shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use proper electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 4723 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the four bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the electric shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 4724 Transfer Case Actuator: Service and Repair Vacuum Reservoir REMOVAL 1. Remove the right front fender splash shield. 1 Remove the screws. 2 Remove the pushpins. 3 Remove the right front fender splash shield. 2. Remove the engine vacuum reservoir. 1 Remove the bolts. 2 Disconnect the vacuum harness from the engine vacuum reservoir and remove the engine vacuum reservoir. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 4725 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 4726 Transfer Case Actuator: Service and Repair Auxiliary Vacuum Reservoir REMOVAL 1. Remove the front fender splash shield. 2. Disconnect the vacuum harness from the auxiliary vacuum reservoir and the A/C vacuum reservoir. 3. Slide the vacuum reservoir assembly out of the battery tray. 4. Separate the A/C vacuum reservoir from the auxiliary vacuum reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation Pressure Regulating Solenoid: Description and Operation ELECTRONIC PRESSURE CONTROL (EPC) SOLENOID The Electronic Pressure Control (EPC) solenoid regulates transmission pressure. EPC valve pressure is used to control line pressure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 4732 Pressure Regulating Solenoid: Service and Repair REMOVAL 1. Remove the manual control lever. 2. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on locking tabs to disconnect the sensors. Disconnect the molded lead frame from the sensors. 1 Disconnect the shift solenoid SSA/SS1 and SSB/SS2. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter connector. 3. Remove the EPC solenoid. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 4733 1. Install the EPC solenoid. 2. Connect the molded lead frame to the sensors. - Connect the bulkhead inter connector. - Connect the Electronic Pressure Control (EPC) solenoid. - Connect the Torque Converter Clutch (TCC). - Connect the shift solenoid SSA/SS1 and SSB/SS2. 3. Install the manual control lever. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications TORQUE SPECIFICATIONS Brake Shift Interlock Solenoid Bolts ........................................................................................................................................ 7-11 Nm (63-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4737 Shift Interlock Solenoid: Service and Repair REMOVAL 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Description and Operation Shift Solenoid: Description and Operation Part 1 Of 2 Part 2 Of 2 SHIFT SOLENOID-SSA/SS1 AND SSB/SS2 Two on/off shift solenoids provide gear selection of first through fourth gears by controlling the pressure to the three shift valves. One unit containing the two shift solenoids is located in the main control valve body. The shift solenoids are two-way normally open style. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TORQUE SPECIFICATIONS TCC Solenoid Bolt ............................................................................................................................... .................................. 9-11 Nm (80-100 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 4744 Torque Converter Clutch Solenoid: Description and Operation Part 1 Of 2 Part 2 Of 2 The Torque Converter Clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 99-18-5 > Sep > 99 > A/T 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Accumulator: Customer Interest A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Article No. 99-18-5 09/06/99 ^ TRANSMISSION CONTROL INDICATOR LAMP (TCIL) - TCIL ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) P0782 STORED IN MEMORY - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 AND WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R70W - DELAYED OR NO 2-3 UPSHIFT - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 FORD: 1997-1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1997-1998 MARK VIII 1997-1999 TOWN CAR MERCURY: 1997-1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to revise the Service Procedure. ISSUE A perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on some vehicles. The Powertrain Control Module (PCM) strategy is designed to delay shifts in some vehicles when Transmission Fluid Temperature (TFT) is below approximately 21°C (70°F) for taster heater warmup. The 2-3 shift may be delayed approximately 14-24 km/h (9-15 mph) when compared to the shift speed charts listed in the appropriate Service or Workshop Manual. A leaking 2-3 accumulator may cause Diagnostic Trouble Code (DTC) P0782. ACTION Verify if delayed upshift is normal cold shift scheduling or a possible leak past the large diameter 2-3 accumulator seal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Using New Generation Star (NGS) Tester, perform all self tests and record DTCs. 2. Monitor rpm, and gear command Parameter Identification Displays (PIDs) with the NGS Tester during the 2-3 shift. 3. If engine rpm decreases within 1-2 seconds after the gear command has changed on the NGS Tester, then vehicle has upshifted properly and no repair is necessary. If engine rpm does not drop within 1-2 seconds, continue to Step 4. 4. If engine rpm does not drop when the PCM commands third gear, then replace the 2-3 accumulator piston using the revised Accumulator Piston (F7AZ-7H292-AB). Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Accumulator Piston OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-1-3 WARRANTY STATUS: Eligible Under the Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991805A Replace Accumulator 1.8 Hrs. Piston Per Service Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 99-18-5 > Sep > 99 > A/T 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift > Page 4753 Procedure (Includes Diagnosis) 991805B Diagnosis Only (Do Not 0.8 Hr. Use With Operation A) DEALER CODING CONDITION BASIC PART NO CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 99-9-6 > May > 99 > A/T 4R70W (Remanufactured) Delayed or No 2-3 Upshift Accumulator: Customer Interest A/T - 4R70W (Remanufactured) Delayed or No 2-3 Upshift Article No. 99-9-6 05/17/99 FORD: 1994-1997 THUNDERBIRD 1995-1998 CROWN VICTORIA 1996-1998 MUSTANG LINCOLN-MERCURY: 1993-1998 MARK VIII 1994-1997 COUGAR 1995-1998 GRAND MARQUIS, TOWN CAR LIGHT TRUCK: 1994-1998 ECONOLINE, F-150 1996-1998 EXPLORER 1997-1998 EXPEDITION, F-25O LD, MOUNTAINEER This concern is ONLY for vehicles with Ford Quality Remanufactured (FQR) 4R70W Transmission Exchange Units With Julian build dates between 062-97 And 04099 (corresponding serial numbers are between R0475797 and R0771887). ISSUE A delayed or no 2-3 upshift, primarily when the transmission is cold, may be evident on some vehicles In some cases, Diagnostic Trouble Code (DTC) P0782 may also be present. This may be caused by fluid pressure leakage past the larger diameter seal of the 2-3 accumulator. ACTION Replace the 2-3 accumulator piston using a revised piston. The revised piston will increase seal/bore interference, eliminating any internal leak relating to the 2-3 accumulator piston reducing the possibility of 2-3 upshift concerns. Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Piston OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 990906A Replace Accumulator 1.0 Hr. Piston DEALER CODING CONDITION BASIC PART NO. CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 98-20-9 > Oct > 98 > A/T E4OD/4R100 Ticking Noise On Start Up Technical Service Bulletin # 98-20-9 Date: 981012 A/T - E4OD/4R100 Ticking Noise On Start Up Article No. 98-20-9 10/12/98 ^ NOISE - "TICKING" OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES WITH E4OD/4R100 TRANSMISSION AND BUILT THROUGH 6/11/98 ^ TRANSMISSION - E4OD/4R100 - "TICKING" NOISE OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES BUILT THROUGH 6/11/98 LIGHT TRUCK: 1998 ECONOLINE, EXPEDITION, F-150, F-250 LD, NAVIGATOR 1999 F-250 HD, F-350, SUPER DUTY F SERIES ISSUE A "ticking" noise on initial startup with shift selector in "P" or "N" position may occur on some vehicles. This may be caused by the overdrive clutch steel separator plate(s) impacting against the case internal spline. ACTION Replace the specified transmission components per the following Service Procedure. NOTE THE TICKING NOISE TYPICALLY IS ONLY PRESENT DURING INITIAL STARTUP AFTER THE VEHICLE HAS SOAKED LONG ENOUGH FOR THE TRANSMISSION FLUID TEMPERATURE TO REACH NEAR THE AMBIENT TEMPERATURE. THIS NOISE MAY BE HEARD INTERMITTENTLY DURING NORMAL OPERATING TEMPERATURES IN OTHER GEAR RANGES. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982009A Replace Specific 5.0 Hrs. Transmission Hardware F-Series LD 4X2 5.4L 982009B Replace Specific 6.8 Hrs. Transmission Hardware - F-Series LD 4X4 5.4L 982009C Replace Specific 5.0 Hrs. Transmission Hardware - Expedition/Navigator 4X2 5.4L 982009D Replace Specific 6.8 Hrs. Transmission Hardware - Expedition/Navigator 4X4 5.4L 982009E Extra Time To Adjust 0.4 Hr. Four-Wheel Air Suspension Ride Height - Expedition/Navigator Only 982009F Replace Specific 4.6 Hrs. Transmission Hardware - E-Series 5.4L or 6.8L Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 98-20-9 > Oct > 98 > A/T E4OD/4R100 Ticking Noise On Start Up > Page 4762 982009G Replace Specific 4.1 Hrs. Transmission Hardware - E-Series 7.3L 982009H Replace Specific 3.9 Hrs. Transmission Hardware - F-Series HD 4X2 5.4L Or 6.8L 982009I Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 5.4L Or 6.8L 982009J Replace Specific 3.8 Hrs. Transmission Hardware - F-Series HD 4X2 7.3L 982009K Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 7.3L DEALER CODING CONDITION BASIC PART NO. CODE 7B164 07 7G422 07 OASIS CODES: 504000, 597997, 702000 Service Procedure 1. Verify vehicle's build date (Job # 1 built through 6/11/98). 2. Allow vehicle to soak long enough (possibly overnight) that the transmission fluid temperature is near the ambient temperature. Perform initial cold startup. 3. Verify ticking noise with the transmission shift selector in "P" (Park) and "N" (Neutral). 4. When ticking noise is confirmed, refer to the Transmission Hardware Application Chart to update transmission hardware as indicated by vehicle/engine application. NOTE FOLLOW ALL OF THE NORMAL SERVICE PROCEDURE AS OUTLINED IN THE APPROPRIATE WORKSHOP MANUAL. NOTE THE BUILD DATE LISTED MAY VARY SLIGHTLY FOR SOME VEHICLE APPLICATIONS. WHEN SERVICE IS REQUIRED ON A Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 98-20-9 > Oct > 98 > A/T E4OD/4R100 Ticking Noise On Start Up > Page 4763 VEHICLE WITH THIS TICK CONCERN, IT IS RECOMMENDED THAT THE TRANSMISSION BE DISASSEMBLED DOWN TO AND INCLUDING THE COAST CLUTCH PRIOR TO PART ORDERING OR PURCHASE. THIS WILL ALLOW VERIFICATION OF THE CORRECT PARTS REQUIRED. INSPECT THE COAST CLUTCH WHEN REMOVED. IF THE COAST CLUTCH CYLINDER IS THE NEW DESIGN STAMPED, WELDED STEEL USE THE -BA LEVEL OVERDRIVE PLATES (REFER TO THE APPLICATION CHART). IF THE COAST CLUTCH CYLINDER IS THE PREVIOUS E4OD CAST IRON DESIGN USE THE -CA LEVEL OVERDRIVE PLATES AND ANY OTHER ASSOCIATED PARTS RECOMMENDED IN THE TRANSMISSION HARDWARE APPLICATION CHART. CAUTION MIXING COMPONENTS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. CAUTION USING COMPONENTS OTHER THAN AS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Accumulator: All Technical Service Bulletins A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Article No. 99-18-5 09/06/99 ^ TRANSMISSION CONTROL INDICATOR LAMP (TCIL) - TCIL ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) P0782 STORED IN MEMORY - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 AND WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R70W - DELAYED OR NO 2-3 UPSHIFT - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 FORD: 1997-1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1997-1998 MARK VIII 1997-1999 TOWN CAR MERCURY: 1997-1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to revise the Service Procedure. ISSUE A perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on some vehicles. The Powertrain Control Module (PCM) strategy is designed to delay shifts in some vehicles when Transmission Fluid Temperature (TFT) is below approximately 21°C (70°F) for taster heater warmup. The 2-3 shift may be delayed approximately 14-24 km/h (9-15 mph) when compared to the shift speed charts listed in the appropriate Service or Workshop Manual. A leaking 2-3 accumulator may cause Diagnostic Trouble Code (DTC) P0782. ACTION Verify if delayed upshift is normal cold shift scheduling or a possible leak past the large diameter 2-3 accumulator seal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Using New Generation Star (NGS) Tester, perform all self tests and record DTCs. 2. Monitor rpm, and gear command Parameter Identification Displays (PIDs) with the NGS Tester during the 2-3 shift. 3. If engine rpm decreases within 1-2 seconds after the gear command has changed on the NGS Tester, then vehicle has upshifted properly and no repair is necessary. If engine rpm does not drop within 1-2 seconds, continue to Step 4. 4. If engine rpm does not drop when the PCM commands third gear, then replace the 2-3 accumulator piston using the revised Accumulator Piston (F7AZ-7H292-AB). Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Accumulator Piston OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-1-3 WARRANTY STATUS: Eligible Under the Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991805A Replace Accumulator 1.8 Hrs. Piston Per Service Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift > Page 4769 Procedure (Includes Diagnosis) 991805B Diagnosis Only (Do Not 0.8 Hr. Use With Operation A) DEALER CODING CONDITION BASIC PART NO CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 99-9-6 > May > 99 > A/T - 4R70W (Remanufactured) Delayed or No 2-3 Upshift Accumulator: All Technical Service Bulletins A/T - 4R70W (Remanufactured) Delayed or No 2-3 Upshift Article No. 99-9-6 05/17/99 FORD: 1994-1997 THUNDERBIRD 1995-1998 CROWN VICTORIA 1996-1998 MUSTANG LINCOLN-MERCURY: 1993-1998 MARK VIII 1994-1997 COUGAR 1995-1998 GRAND MARQUIS, TOWN CAR LIGHT TRUCK: 1994-1998 ECONOLINE, F-150 1996-1998 EXPLORER 1997-1998 EXPEDITION, F-25O LD, MOUNTAINEER This concern is ONLY for vehicles with Ford Quality Remanufactured (FQR) 4R70W Transmission Exchange Units With Julian build dates between 062-97 And 04099 (corresponding serial numbers are between R0475797 and R0771887). ISSUE A delayed or no 2-3 upshift, primarily when the transmission is cold, may be evident on some vehicles In some cases, Diagnostic Trouble Code (DTC) P0782 may also be present. This may be caused by fluid pressure leakage past the larger diameter seal of the 2-3 accumulator. ACTION Replace the 2-3 accumulator piston using a revised piston. The revised piston will increase seal/bore interference, eliminating any internal leak relating to the 2-3 accumulator piston reducing the possibility of 2-3 upshift concerns. Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Piston OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 990906A Replace Accumulator 1.0 Hr. Piston DEALER CODING CONDITION BASIC PART NO. CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up Technical Service Bulletin # 98-20-9 Date: 981012 A/T - E4OD/4R100 Ticking Noise On Start Up Article No. 98-20-9 10/12/98 ^ NOISE - "TICKING" OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES WITH E4OD/4R100 TRANSMISSION AND BUILT THROUGH 6/11/98 ^ TRANSMISSION - E4OD/4R100 - "TICKING" NOISE OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES BUILT THROUGH 6/11/98 LIGHT TRUCK: 1998 ECONOLINE, EXPEDITION, F-150, F-250 LD, NAVIGATOR 1999 F-250 HD, F-350, SUPER DUTY F SERIES ISSUE A "ticking" noise on initial startup with shift selector in "P" or "N" position may occur on some vehicles. This may be caused by the overdrive clutch steel separator plate(s) impacting against the case internal spline. ACTION Replace the specified transmission components per the following Service Procedure. NOTE THE TICKING NOISE TYPICALLY IS ONLY PRESENT DURING INITIAL STARTUP AFTER THE VEHICLE HAS SOAKED LONG ENOUGH FOR THE TRANSMISSION FLUID TEMPERATURE TO REACH NEAR THE AMBIENT TEMPERATURE. THIS NOISE MAY BE HEARD INTERMITTENTLY DURING NORMAL OPERATING TEMPERATURES IN OTHER GEAR RANGES. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982009A Replace Specific 5.0 Hrs. Transmission Hardware F-Series LD 4X2 5.4L 982009B Replace Specific 6.8 Hrs. Transmission Hardware - F-Series LD 4X4 5.4L 982009C Replace Specific 5.0 Hrs. Transmission Hardware - Expedition/Navigator 4X2 5.4L 982009D Replace Specific 6.8 Hrs. Transmission Hardware - Expedition/Navigator 4X4 5.4L 982009E Extra Time To Adjust 0.4 Hr. Four-Wheel Air Suspension Ride Height - Expedition/Navigator Only 982009F Replace Specific 4.6 Hrs. Transmission Hardware - E-Series 5.4L or 6.8L Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up > Page 4778 982009G Replace Specific 4.1 Hrs. Transmission Hardware - E-Series 7.3L 982009H Replace Specific 3.9 Hrs. Transmission Hardware - F-Series HD 4X2 5.4L Or 6.8L 982009I Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 5.4L Or 6.8L 982009J Replace Specific 3.8 Hrs. Transmission Hardware - F-Series HD 4X2 7.3L 982009K Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 7.3L DEALER CODING CONDITION BASIC PART NO. CODE 7B164 07 7G422 07 OASIS CODES: 504000, 597997, 702000 Service Procedure 1. Verify vehicle's build date (Job # 1 built through 6/11/98). 2. Allow vehicle to soak long enough (possibly overnight) that the transmission fluid temperature is near the ambient temperature. Perform initial cold startup. 3. Verify ticking noise with the transmission shift selector in "P" (Park) and "N" (Neutral). 4. When ticking noise is confirmed, refer to the Transmission Hardware Application Chart to update transmission hardware as indicated by vehicle/engine application. NOTE FOLLOW ALL OF THE NORMAL SERVICE PROCEDURE AS OUTLINED IN THE APPROPRIATE WORKSHOP MANUAL. NOTE THE BUILD DATE LISTED MAY VARY SLIGHTLY FOR SOME VEHICLE APPLICATIONS. WHEN SERVICE IS REQUIRED ON A Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up > Page 4779 VEHICLE WITH THIS TICK CONCERN, IT IS RECOMMENDED THAT THE TRANSMISSION BE DISASSEMBLED DOWN TO AND INCLUDING THE COAST CLUTCH PRIOR TO PART ORDERING OR PURCHASE. THIS WILL ALLOW VERIFICATION OF THE CORRECT PARTS REQUIRED. INSPECT THE COAST CLUTCH WHEN REMOVED. IF THE COAST CLUTCH CYLINDER IS THE NEW DESIGN STAMPED, WELDED STEEL USE THE -BA LEVEL OVERDRIVE PLATES (REFER TO THE APPLICATION CHART). IF THE COAST CLUTCH CYLINDER IS THE PREVIOUS E4OD CAST IRON DESIGN USE THE -CA LEVEL OVERDRIVE PLATES AND ANY OTHER ASSOCIATED PARTS RECOMMENDED IN THE TRANSMISSION HARDWARE APPLICATION CHART. CAUTION MIXING COMPONENTS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. CAUTION USING COMPONENTS OTHER THAN AS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 4780 Accumulator: Locations Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 4781 Accumulator: Description and Operation Part 1 Of 2 Part 2 Of 2 The transmission uses two accumulators: 1-2 Accumulator-The 1-2 accumulator is used to soften the 1-2 shift by absorbing some of the pressure directed to the intermediate clutch. Constant line pressure is applied to the middle section of the 1-2 accumulator piston, opposing the intermediate clutch pressure, until the pressure is high enough to overcome line pressure. The top of the piston is exhausted to the sump. - 2-3 Accumulator-The 2-3 accumulator is used to soften the 2-3 shift by absorbing some of the direct clutch pressure. Forward clutch pressure is applied to the top side of the 2-3 accumulator piston, holding the piston down until clutch pressure is high enough to overcome it. The middle section of the piston is exhausted to the sump. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Special Tools REMOVAL 1. Use (A) Servo Piston Remover Replacer to compress the 1-2 accumulator cover and remove the (B) accumulator piston retaining ring. 2. NOTE: Note the location of the 1-2 accumulator springs for reference during assembly. 1 Remove the l-2 accumulator cover. 2 Remove the lower 1-2 accumulator spring. 3 Remove the accumulator piston. 4 Remove the upper 1-2 accumulator spring. INSTALLATION 1. Install the 1-2 accumulator. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 Accumulator > Page 4784 1 Install the 1-2 accumulator upper spring. 2 Install the accumulator piston. 3 Install the 1-2 accumulator lower spring. 4 Install the cover and seal assembly. 2. Use (A) Servo Piston Remover Replacer to install the (B) accumulator piston retaining ring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 Accumulator > Page 4785 Accumulator: Service and Repair 2-3 Accumulator REMOVAL 1. Remove the main control valve body. 2. Remove the 2-3 accumulator piston retaining ring. 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Description and Operation Band: Description and Operation BAND-OVERDRIVE The overdrive band holds the reverse clutch drum in stationary fourth gear and in manual range second gear. This action causes the reverse sun gear to be held in these ranges. BAND-LOW AND REVERSE The (A) low and reverse band holds the (B) pinion carrier in reverse. It also applies in 1st gear and manual 1 position to provide engine braking. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo Band Apply Servo: Service and Repair Overdrive Servo Special Tools REMOVAL 1. Remove the main control valve body. 2. NOTE: If 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. Use (A) Servo Piston Remover/Replacer to compress the servo spring then remove the (B) overdrive servo retaining ring. 3. Remove the (A) overdrive servo piston and the (B) overdrive servo piston return spring. INSTALLATION 1. Install the overdrive servo piston assembly. 1 Install the overdrive servo piston return spring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo > Page 4793 2 Install the overdrive servo piston assembly. 2. Use (A) Servo Piston Remover/Replacer Tool to install the (B) overdrive servo piston retaining ring. 3. Install the main control valve body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo > Page 4794 Band Apply Servo: Service and Repair Reverse Servo Assembly Special Tools REMOVAL 1. Remove the main control valve body. 2. Use the Servo Piston Remover/Replacer to remove the reverse band servo retaining ring. 1 Compress the servo spring. 2 Remove the reverse band servo retaining ring. 3. NOTE: The length of the rod attached to the piston is graded for three different lengths. Therefore, they should not be installed in any transmission other than the transmission from which they were removed. Remove the (A) reverse band servo cover, (B) reverse band servo piston and rod and (C) reverse band servo spring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo > Page 4795 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 piston and return spring. Do not install piston cover. 2. Install Servo Piston Selection Tool and tighten the band apply bolt. 3. Attach Dial Indicator With Bracketry. - Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator. 4. Loosen the bolt until the piston stops against the tool. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo > Page 4796 5. Verify the amount of piston travel on the dial indicator is within specification. 6. If piston travel is not within specification, select the proper servo assembly (A) one groove, (B) two groove or (C) three groove, to bring the servo piston travel within specification. 7. Remove the dial indicator and servo selection tool. 8. Install the proper servo piston assembly spring and the reverse servo piston cover and seal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo > Page 4797 9. Use the Servo Piston Remover/Replacer to 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up Technical Service Bulletin # 98-20-9 Date: 981012 A/T - E4OD/4R100 Ticking Noise On Start Up Article No. 98-20-9 10/12/98 ^ NOISE - "TICKING" OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES WITH E4OD/4R100 TRANSMISSION AND BUILT THROUGH 6/11/98 ^ TRANSMISSION - E4OD/4R100 - "TICKING" NOISE OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES BUILT THROUGH 6/11/98 LIGHT TRUCK: 1998 ECONOLINE, EXPEDITION, F-150, F-250 LD, NAVIGATOR 1999 F-250 HD, F-350, SUPER DUTY F SERIES ISSUE A "ticking" noise on initial startup with shift selector in "P" or "N" position may occur on some vehicles. This may be caused by the overdrive clutch steel separator plate(s) impacting against the case internal spline. ACTION Replace the specified transmission components per the following Service Procedure. NOTE THE TICKING NOISE TYPICALLY IS ONLY PRESENT DURING INITIAL STARTUP AFTER THE VEHICLE HAS SOAKED LONG ENOUGH FOR THE TRANSMISSION FLUID TEMPERATURE TO REACH NEAR THE AMBIENT TEMPERATURE. THIS NOISE MAY BE HEARD INTERMITTENTLY DURING NORMAL OPERATING TEMPERATURES IN OTHER GEAR RANGES. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982009A Replace Specific 5.0 Hrs. Transmission Hardware F-Series LD 4X2 5.4L 982009B Replace Specific 6.8 Hrs. Transmission Hardware - F-Series LD 4X4 5.4L 982009C Replace Specific 5.0 Hrs. Transmission Hardware - Expedition/Navigator 4X2 5.4L 982009D Replace Specific 6.8 Hrs. Transmission Hardware - Expedition/Navigator 4X4 5.4L 982009E Extra Time To Adjust 0.4 Hr. Four-Wheel Air Suspension Ride Height - Expedition/Navigator Only 982009F Replace Specific 4.6 Hrs. Transmission Hardware - E-Series 5.4L or 6.8L Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up > Page 4806 982009G Replace Specific 4.1 Hrs. Transmission Hardware - E-Series 7.3L 982009H Replace Specific 3.9 Hrs. Transmission Hardware - F-Series HD 4X2 5.4L Or 6.8L 982009I Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 5.4L Or 6.8L 982009J Replace Specific 3.8 Hrs. Transmission Hardware - F-Series HD 4X2 7.3L 982009K Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 7.3L DEALER CODING CONDITION BASIC PART NO. CODE 7B164 07 7G422 07 OASIS CODES: 504000, 597997, 702000 Service Procedure 1. Verify vehicle's build date (Job # 1 built through 6/11/98). 2. Allow vehicle to soak long enough (possibly overnight) that the transmission fluid temperature is near the ambient temperature. Perform initial cold startup. 3. Verify ticking noise with the transmission shift selector in "P" (Park) and "N" (Neutral). 4. When ticking noise is confirmed, refer to the Transmission Hardware Application Chart to update transmission hardware as indicated by vehicle/engine application. NOTE FOLLOW ALL OF THE NORMAL SERVICE PROCEDURE AS OUTLINED IN THE APPROPRIATE WORKSHOP MANUAL. NOTE THE BUILD DATE LISTED MAY VARY SLIGHTLY FOR SOME VEHICLE APPLICATIONS. WHEN SERVICE IS REQUIRED ON A Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up > Page 4807 VEHICLE WITH THIS TICK CONCERN, IT IS RECOMMENDED THAT THE TRANSMISSION BE DISASSEMBLED DOWN TO AND INCLUDING THE COAST CLUTCH PRIOR TO PART ORDERING OR PURCHASE. THIS WILL ALLOW VERIFICATION OF THE CORRECT PARTS REQUIRED. INSPECT THE COAST CLUTCH WHEN REMOVED. IF THE COAST CLUTCH CYLINDER IS THE NEW DESIGN STAMPED, WELDED STEEL USE THE -BA LEVEL OVERDRIVE PLATES (REFER TO THE APPLICATION CHART). IF THE COAST CLUTCH CYLINDER IS THE PREVIOUS E4OD CAST IRON DESIGN USE THE -CA LEVEL OVERDRIVE PLATES AND ANY OTHER ASSOCIATED PARTS RECOMMENDED IN THE TRANSMISSION HARDWARE APPLICATION CHART. CAUTION MIXING COMPONENTS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. CAUTION USING COMPONENTS OTHER THAN AS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 98-20-9 > Oct > 98 > A/T E4OD/4R100 Ticking Noise On Start Up Technical Service Bulletin # 98-20-9 Date: 981012 A/T - E4OD/4R100 Ticking Noise On Start Up Article No. 98-20-9 10/12/98 ^ NOISE - "TICKING" OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES WITH E4OD/4R100 TRANSMISSION AND BUILT THROUGH 6/11/98 ^ TRANSMISSION - E4OD/4R100 - "TICKING" NOISE OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES BUILT THROUGH 6/11/98 LIGHT TRUCK: 1998 ECONOLINE, EXPEDITION, F-150, F-250 LD, NAVIGATOR 1999 F-250 HD, F-350, SUPER DUTY F SERIES ISSUE A "ticking" noise on initial startup with shift selector in "P" or "N" position may occur on some vehicles. This may be caused by the overdrive clutch steel separator plate(s) impacting against the case internal spline. ACTION Replace the specified transmission components per the following Service Procedure. NOTE THE TICKING NOISE TYPICALLY IS ONLY PRESENT DURING INITIAL STARTUP AFTER THE VEHICLE HAS SOAKED LONG ENOUGH FOR THE TRANSMISSION FLUID TEMPERATURE TO REACH NEAR THE AMBIENT TEMPERATURE. THIS NOISE MAY BE HEARD INTERMITTENTLY DURING NORMAL OPERATING TEMPERATURES IN OTHER GEAR RANGES. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982009A Replace Specific 5.0 Hrs. Transmission Hardware F-Series LD 4X2 5.4L 982009B Replace Specific 6.8 Hrs. Transmission Hardware - F-Series LD 4X4 5.4L 982009C Replace Specific 5.0 Hrs. Transmission Hardware - Expedition/Navigator 4X2 5.4L 982009D Replace Specific 6.8 Hrs. Transmission Hardware - Expedition/Navigator 4X4 5.4L 982009E Extra Time To Adjust 0.4 Hr. Four-Wheel Air Suspension Ride Height - Expedition/Navigator Only 982009F Replace Specific 4.6 Hrs. Transmission Hardware - E-Series 5.4L or 6.8L Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 98-20-9 > Oct > 98 > A/T E4OD/4R100 Ticking Noise On Start Up > Page 4813 982009G Replace Specific 4.1 Hrs. Transmission Hardware - E-Series 7.3L 982009H Replace Specific 3.9 Hrs. Transmission Hardware - F-Series HD 4X2 5.4L Or 6.8L 982009I Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 5.4L Or 6.8L 982009J Replace Specific 3.8 Hrs. Transmission Hardware - F-Series HD 4X2 7.3L 982009K Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 7.3L DEALER CODING CONDITION BASIC PART NO. CODE 7B164 07 7G422 07 OASIS CODES: 504000, 597997, 702000 Service Procedure 1. Verify vehicle's build date (Job # 1 built through 6/11/98). 2. Allow vehicle to soak long enough (possibly overnight) that the transmission fluid temperature is near the ambient temperature. Perform initial cold startup. 3. Verify ticking noise with the transmission shift selector in "P" (Park) and "N" (Neutral). 4. When ticking noise is confirmed, refer to the Transmission Hardware Application Chart to update transmission hardware as indicated by vehicle/engine application. NOTE FOLLOW ALL OF THE NORMAL SERVICE PROCEDURE AS OUTLINED IN THE APPROPRIATE WORKSHOP MANUAL. NOTE THE BUILD DATE LISTED MAY VARY SLIGHTLY FOR SOME VEHICLE APPLICATIONS. WHEN SERVICE IS REQUIRED ON A Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 98-20-9 > Oct > 98 > A/T E4OD/4R100 Ticking Noise On Start Up > Page 4814 VEHICLE WITH THIS TICK CONCERN, IT IS RECOMMENDED THAT THE TRANSMISSION BE DISASSEMBLED DOWN TO AND INCLUDING THE COAST CLUTCH PRIOR TO PART ORDERING OR PURCHASE. THIS WILL ALLOW VERIFICATION OF THE CORRECT PARTS REQUIRED. INSPECT THE COAST CLUTCH WHEN REMOVED. IF THE COAST CLUTCH CYLINDER IS THE NEW DESIGN STAMPED, WELDED STEEL USE THE -BA LEVEL OVERDRIVE PLATES (REFER TO THE APPLICATION CHART). IF THE COAST CLUTCH CYLINDER IS THE PREVIOUS E4OD CAST IRON DESIGN USE THE -CA LEVEL OVERDRIVE PLATES AND ANY OTHER ASSOCIATED PARTS RECOMMENDED IN THE TRANSMISSION HARDWARE APPLICATION CHART. CAUTION MIXING COMPONENTS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. CAUTION USING COMPONENTS OTHER THAN AS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch Clutch: Specifications Direct Clutch GENERAL SPECIFICATIONS Clearance: 1.270-1.372 mm (0.050-0.054 inch), 1.625-1.727 mm (0.064-0.068 inch), 1.981-2.083 mm (0.078-0.082 inch), 2.337-2.438 mm (0.092-0.096 inch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch > Page 4817 Clutch: Specifications Forward Clutch GENERAL SPECIFICATIONS Clearance ............................................................................................................................................ ........................... 1.28-2.38 mm (0.050-0.094 inch) Snap Ring Thickness: 1.524-1.625 mm (0.060-0.064 inch), 1.880-1.981 mm (0.074-0.078 inch), 2.235-2.337 mm (0.088-0.092 inch), 2.591-2.692 mm (0.102-0.106 inch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch > Page 4818 Clutch: Specifications Intermediate Clutch GENERAL SPECIFICATIONS Clearance ........................................................................................................................................................... 42.5958-41.7322 mm (1.677-1.643 inch) Snap Ring Thickness: 1.702-1.803 mm (0.067-0.071 inch), 1.956-2.057 mm (0.077-0.081 inch), 2.210-2.311 mm (0.087-0.091 inch), 2.464-2.565 mm (0.097-0.101 inch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch > Page 4819 Clutch: Specifications Reverse Clutch GENERAL SPECIFICATIONS Clearance ............................................................................................................................................ ....................... 2.845-6.020 mm (0.072-0.112 inch) Snap Ring Thickness: 1.524-1.625 mm (0.060-0.064 inch), 1.880-1.981 mm (0.074-0078 inch), 2.235-2.337 mm (0.088-0.092 inch), 2.591-2.692 mm (0.102-0.106 inch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Direct Clutch Direct Clutch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Direct Clutch > Page 4822 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Direct Clutch > Page 4823 Clutch: Diagrams Intermediate Clutch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Direct Clutch > Page 4824 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Page 4825 Clutch: Description and Operation CLUTCH-INTERMEDIATE The intermediate clutch works with the intermediate one-way clutch to hold the sun gear stationary in second gear. It remains applied in third and fourth gears, but does not transmit power. CLUTCH-FORWARD The forward clutch couples the forward clutch cylinder and input shaft to the forward sun gear in all forward gears. CLUTCH-DIRECT The (A) direct clutch couples the input shaft to the (B) planet carrier through the (C) stub shaft in third and fourth gears. CLUTCH-REVERSE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Page 4826 The (A) reverse clutch couples the (B) input shaft to the (C) reverse sun gear, it is applied in reverse range only. ONE-WAY CLUTCH-PLANETARY (LOW) The (A) planetary (low) one-way clutch is a roller clutch that holds the (B) planetary gearset in first gear, (D) and D ranges. During automatic coasting downshifts into first gear (D) and D ranges), it freewheels so that there is no engine braking. ONE-WAY CLUTCH-INTERMEDIATE The intermediate one-way clutch is a roller clutch that works with the intermediate friction clutch to hold the reverse clutch drum and reverse sun gear stationary in second gear during acceleration. It freewheels in third gear and during coasting in second gear, (D) and D ranges. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch Clutch: Service and Repair Direct Clutch Special Tools Output Shaft, Direct Clutch Cylinder And Ring Gear Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4829 Direct Clutch DISASSEMBLY 1. Remove the ring gear snap ring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4830 2. Separate the (A) ring gear and (B) output shaft. 3. Remove the three output shaft seal rings. 4. Remove the (A) output shaft hub snap ring and the (B) output shaft hub. 5. Remove the two direct clutch seal rings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4831 6. Remove the (A) direct clutch hub and the (B) bearing and direct clutch inner bearing support. 7. Inspect clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Replace clutch cylinder if badly scored or damaged. 8. Check fluid passage in clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and replace if necessary. Inspect check balls for freedom of movement and proper seating. 9. Check clutch release spring for distortion and cracks. Replace spring (including wave spring) if distorted or cracked. 10. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Replace all parts that are deeply scored or burred. 11. Check clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat. 12. Check clutch hub thrust surfaces for scores and clutch hub splines for wear. 13. Remove the (1) direct clutch pack retaining ring and the (2) direct clutch pack. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4832 14. Use (A) Clutch Spring Compressor to compress the piston return spring and remove the (B) snap ring. 15. WARNING: WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. NOTE: If necessary, use regulated compressed air (207 kPa [30 psi] max pressure) to remove the clutch piston. Remove the support and spring assembly and piston. 16. Remove the inner piston seal. 17. Remove the outer piston seal. ASSEMBLY Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4833 1. NOTE: Lubricate direct clutch piston inner seal and seal protector with petroleum jelly. Position (A) Direct Clutch Lip Seal Protector over the clutch cylinder hub and install the (B) inner piston seal. Install the seal with sealing lip facing down. 2. Install the clutch piston outer seal so that when the piston is installed the sealing lip points toward the bottom of the cylinder. 3. NOTE: Coat inner and outer direct clutch piston seals, clutch cylinder sealing area and piston inner sealing area with petroleum jelly. Use (A) Direct Clutch Lip Seal Protector to install the (B) direct clutch piston. 4. Install the piston return spring and retainer assembly. 5. Use (A) Clutch Spring Compressor to compress the piston return spring and install the (B) retaining ring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4834 6. NOTE: Before assembly, soak new clutch discs in transmission fluid for 15 minutes. Install the (A) clutch pack and the (B) clutch pack retaining ring. Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the steel pressure plate. 7. Use a (A) feeler gauge to check the clearance between the (B) clutch pack retaining ring and the (C) pressure plate. - If the clearance is not within specifications, install the correct size retaining ring and recheck clearance. 8. Install the washer and the (B) No. 7 needle bearing on the (A) direct clutch hub and install the direct clutch hub. - Install the needle bearing with the black side up, toward direct clutch hub. NOTE: Inspect the output shaft bearing surfaces for scores. Inspect the output shaft splines for wear. Inspect all bushings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4835 9. CAUTION: Make sure seals are lapped correctly. Internal damage may occur. Install the two direct clutch seal rings. 10. Install the output shaft hub. - Position the output shaft hub. - Install the retaining ring. 11. Install the three output shaft seal rings. 12. Install the No. 8 needle bearing on the direct clutch cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4836 13. NOTE: Direct clutch cylinder may be installed after the output shaft ring gear is installed to the output shaft hub. Assemble the direct clutch on the output shaft. 14. Install the ring gear on the output shaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4837 Clutch: Service and Repair Forward Clutch Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4838 DISASSEMBLY 1. Inspect clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Replace clutch cylinder if badly scored or damaged. 2. Check fluid passage in clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and replace if necessary. Inspect check balls for freedom of movement and proper seating. 3. Check clutch release spring for distortion and cracks. Replace spring (including wave spring) if distorted or cracked. 4. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Replace all parts that are deeply scored or burred. 5. Check clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat. 6. Check clutch hub thrust surfaces for scores and clutch hub splines for wear. 7. NOTE: The forward clutch hub may remain in shell during disassembly. Remove the (A) forward clutch hub and the (B) No. 3 forward clutch hub front bearing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4839 8. NOTE: To aid handling, the forward clutch assembly may be set in the extension housing or a hole in the work bench. Remove the clutch pack selective retaining ring. 9. Remove the (A) pressure plate, (B) clutch pack and (C) pressure spring. 10. CAUTION: Apply only enough pressure to release pressure on the retaining ring. If too much pressure is applied, the spring may break. Use (A) Direct Clutch Spring Compressor and an arbor press to remove the (B) forward clutch retaining ring. 11. Slowly release the press and remove the forward clutch from the press. 12. Remove the (A) forward clutch retainer and the (B) return spring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4840 13. NOTE: Air pressure may be required to remove the forward clutch piston. Remove the forward clutch piston. 14. Remove the (A) inner and (B) outer forward clutch piston seals. 15. NOTE: The seals are solid seals but will be replaced with scarf cut seals. Remove the forward clutch input shaft seals. 16. Make sure the check ball in the clutch cylinder is free and clean. Check for proper seating. ASSEMBLY 1. Inspect clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Replace clutch cylinder if badly scored or damaged. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4841 2. Check fluid passage in clutch cylinder for Obstructions. Clean out all fluid passages. Inspect clutch piston for scores and replace if necessary. Inspect check balls for freedom of movement and proper seating. 3. Check clutch release spring for distortion and cracks. Replace spring (including wave spring) if distorted or cracked. 4. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Replace all parts that are deeply scored or burred. 5. Check clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat. 6. Check clutch hub thrust surfaces for scores and clutch hub splines for wear. NOTE: To aid handling, the forward clutch assembly may be set in the extension housing or a hole in the work bench. 7. Install the (A) inner and (B) outer forward clutch piston seals. Note the direction of the sealing rings before installation. 8. NOTE: Coat the piston seals and clutch drum sealing area with petroleum jelly. Position (A) Forward Clutch Lip Seal Protector (Inner) on the clutch cylinder hub and (B) Forward Clutch Lip Seal Protector (Outer) on the clutch piston. 9. Install the forward clutch piston into the clutch drum. - Push the piston to the bottom of the drum using even pressure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4842 10. Position the (A) pressure plate, (B) clutch pack and the (C) piston return spring and retainer. 11. Use (A) Direct Clutch Spring Compressor and an arbor press to compress the piston return spring and install the (B) retaining ring. 12. Slowly release the press pressure and remove the forward clutch. 13. NOTE: Before assembly, soak new clutch discs in transmission fluid for 15 minutes. Install the clutch pack assembly. 1 Install the pressure ring. 2 Install the clutch pack. 3 Install the pressure plate. 14. Install the clutch pack retaining ring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4843 15. Position and zero Dial Indicator With Bracketry on the forward clutch pack. - Push downward on the clutch pack. - Release pressure and zero the dial indicator. 16. Check the clutch pack clearance. 1 Lift up on the clutch pack until it fully seats against the clutch pressure plate retainer. 2 Read the dial indicator. - If the clearance is not within specifications, install the correct size retaining ring. Selective Retaining Ring 17. NOTE: Make sure scarf-cut seals are mated correctly. Slide the two scarf-cut seals on the input shaft. (A) is correct; (B) is incorrect mating. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4844 18. Install the two scarf-cut on input shaft. 19. Install the (A) No. 3 forward clutch hub front bearing and the (B) forward clutch hub. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4845 Clutch: Service and Repair Intermediate Clutch Intermediate Clutch Cylinder DISASSEMBLY 1. Lift to remove intermediate clutch hub. ASSEMBLY 1. NOTE: For ease of assembly, the chamfer on the intermediate clutch hub splices should face upward. NOTE: The clutch hub must rotate counterclockwise when installed on the reverse clutch drum. Install the intermediate clutch hub. Pump and Intermediate Clutch Piston Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4846 Special Tools DISASSEMBLY Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4847 1. Remove the No. 1 pump support thrust washer. 2. Remove the front pump support. 1 Remove the bolts. 2 Remove the front pump support. 3. NOTE: The reverse clutch cylinder seals are larger than the forward clutch cylinder rings. Remove the two (A) reverse clutch cylinder seals and the two (B) forward clutch cylinder seals. 4. Remove the (A) inner and (B) outer pump gerotor gears. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4848 5. Carefully pry spring retainer tabs and remove the spring retainer assembly. 6. Remove the intermediate clutch piston. 7. Replace the clutch piston seals. 1 Remove the intermediate clutch piston outer seal. 2 Remove the intermediate clutch piston inner seal. 8. Remove and discard the front pump seal. ASSEMBLY Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4849 1. Use (A) Front Pump Seal Replacer to install the (B) front pump seal assembly. 2. Install the clutch piston seals. 1 Install the intermediate clutch piston outer seal. 2 Install the intermediate clutch piston inner seal. 3. NOTE: Coat the intermediate clutch piston outer seal, intermediate clutch piston inner seal and pump body sealing area with petroleum jelly. Install the (A) intermediate clutch piston into (B) Clutch Lip Seal Protector. 4. Install the intermediate clutch piston. 1 Position the intermediate clutch piston and Clutch Lip Seal Protector onto the pump body. 2 Push the intermediate clutch piston to the bottom of the pump body bore, exerting even pressure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4850 5. CAUTION: The piston bleed hole must be located at 12 o'clock position (towards the top of the transmission). Shift problems may occur if installed incorrectly. NOTE: The piston bleed hole is the only round hole in the pump body. Locate the piston bleed hole. 6. Install by snapping the spring retainer assembly on pump body. 7. NOTE: The flats on the inner fluid pump gear have steps that must face the pump body for ease of installing the torque converter. Install the (A) inner and (B) outer fluid pump gerotor gears. 8. NOTE: The reverse clutch cylinder seals are larger than the forward clutch cylinder seals. Install the (A) reverse clutch cylinder seal and the (B) forward clutch cylinder seals. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4851 9. Install new front pump seal. 10. Assemble the front pump. 1 Position the pump support to the pump body assembly. 2 Install the bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4852 Clutch: Service and Repair Reverse Clutch Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4853 DISASSEMBLY 1. Inspect clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Replace clutch cylinder if badly scored or damaged. 2. Check fluid passage in clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and replace if necessary. Inspect check balls for freedom of movement and proper seating. 3. Check clutch release spring for distortion and cracks. Replace spring (including wave spring) if distorted or cracked. 4. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Replace all parts that are deeply scored or burred. 5. Check clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat. 6. Check clutch hub thrust surfaces for scores and clutch hub splines for wear. 7. Remove the No. 2 forward clutch bearing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4854 8. Remove the reverse clutch pressure plate retainer. 9. Remove the reverse clutch pack. 10. Use (A) Reverse Clutch Spring Compressor and (B) Clutch Spring Compressor to compress the (C) reverse clutch piston spring. 11. Remove the reverse clutch piston spring retaining ring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4855 12. Remove the (A) reverse clutch piston spring and the (B) reverse clutch piston spring pressure ring. 13. NOTE: To ease reverse clutch piston removal, it may be necessary to apply air pressure to the reverse clutch drum. Block the opposite hole. Remove the reverse clutch piston. 14. Remove the (A) reverse clutch piston inner seal and the (B) reverse clutch piston outer seal. ASSEMBLY 1. Inspect clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Replace clutch cylinder if badly scored or damaged. 2. Check fluid passage in clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and replace if necessary. Inspect check balls for freedom of movement and proper seating. 3. Check clutch release spring for distortion and cracks. Replace spring (including wave spring) if distorted or cracked. 4. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Replace all parts that are deeply scored or burred. 5. Check clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat. 6. Check clutch hub thrust surfaces for scores and clutch hub splines for wear. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4856 7. NOTE: The piston check ball must be present and moving freely. Install a new (A) reverse clutch piston inner seal and (B) reverse clutch piston outer seal. 8. NOTE: Coat the reverse clutch piston inner seal, reverse clutch piston outer seal reverse clutch drum sealing area and seal protector with petroleum jelly. Install the reverse clutch piston. 1 Position Reverse Clutch Inner Seal Protector on the clutch hub. 2 Place Reverse Clutch Outer Seal Protector over reverse clutch piston. 3 Position the reverse clutch piston and use even pressure to push it to the bottom of the reverse clutch drum. 9. NOTE: The dished side of the reverse clutch piston spring must face the reverse clutch piston. Install the (A) pressure ring and the (B) reverse clutch piston spring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4857 10. Use (A) Reverse Clutch Spring Compressor and (B) Clutch Spring Compressor to compress the (C) reverse clutch piston spring. 11. Install the reverse clutch piston spring retaining ring. 12. Remove Reverse Clutch Spring Compressor and Clutch Spring Compressor. 13. NOTE: Before assembly, soak new clutch discs in transmission fluid for 15 minutes. NOTE: Install the pressure plates with the flat sides facing the clutch pack. Install the reverse clutch front pressure plate, clutch pack and reverse clutch rear pressure plate. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4858 14. Install the reverse clutch pressure plate retainer snap ring. 15. Position and zero Dial Indicator With Bracketry on the reverse clutch pack. - Push downward on the clutch pack. - Release pressure and zero the dial indicator. 16. Check the reverse clutch pack clearance. 1 Lift up on the clutch pack until it fully seats against the reverse clutch pressure plate retainer. 2 Read the dial indicator. - If clearance is not within specifications, install the correct size retaining ring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4859 17. Check the clutch for proper operation. - Apply air pressure to the reverse clutch drum. The clutch should be heard and felt to work without leakage. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Specifications Automatic Transmission Dipstick - Dipstick Tube: Specifications TORQUE SPECIFICATIONS Transmission Fluid Filler Tube Bolt .................................................................................................................................... 18-23 Nm (13.5-16.5 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Specifications > Page 4863 Automatic Transmission Dipstick - Dipstick Tube: Service and Repair REMOVAL 1. Remove the transmission fluid filler tube bolt from the side of the RH cylinder head. 2. Remove the fluid filler tube. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications TORQUE SPECIFICATIONS Extension Housing Bolts ............................................................................................................................................................ 25-30 Nm (18-22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 4867 Extension Housing: Service and Repair NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. Special Tools REMOVAL 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise and support the vehicle. 4. Drain the transmission fluid. 5. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original positions. Remove the rear driveshaft. 1 Remove the four bolts. 2 Remove the rear driveshaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 4868 6. Remove the Vehicle Speed Sensor (VSS). 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the VSS. 7. Use High-Lift Jack to support the transmission. 8. Remove the nuts 9. Remove the bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 4869 10. Remove the transmission crossmember. 1 Remove the bolts. 2 Remove the transmission crossmember. 11. Lower the transmission to access the extension housing bolts. 12. Use (A) Seal Remover and (B) Impact Slide Hammer to remove the (C) extension housing seal. 13. Remove the extension housing and gasket. 1 Remove the bolts and nuts. 2 Remove the extension housing and gasket. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 4870 1. Install the extension housing and gasket. 1 Position the extension housing gasket and the extension housing. 2 Install the bolts and nuts. 2. Install the new extension housing seal. 1 Align Extension Housing Seal Replacer with the seal. 2 Install the extension housing seal. 3. Raise and position the transmission. 4. Install the transmission crossmember. 1 Position the transmission crossmember. 2 Install the bolts. 5. Install the transmission crossmember bolts. 6. Remove High-Lift Jack. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 4871 7. Install the nuts. 8. Install the VSS. 1 Install the VSS. 2 Install the bolt. 3 Connect the electrical connector. 9. Lower the vehicle. 10. Connect the battery ground cable. 11. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 4876 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 4877 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications With E4OD Transmission A/T Fluid 4x2 ....................................................................................................................................... ........................................................... 15L (15.9 Qt) A/T Fluid 4x4 ....................................................................................................................................... ........................................................ 15.5L (16.4 Qt) NOTE: With engine at operating temperature, shift through all gears. Check fluid in PARK add fluid as needed. With 4R70W Transmission A/T Fluid .............................................................................................................................................. ......................................................... 13.1L (13.9 Qt) NOTE: With engine at operating temperature, shift through all gears. Check fluid in PARK add fluid as needed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4880 Fluid - A/T: Fluid Type Specifications NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. Automatic (4R70W) ............................................................................................................................. ..................................................... MERCON V ATF Automatic (4R100) ............................................................................................................................................................. MERCON or MERCON V ATF Automatic (E40D) ............................................................................................................................................................. MERCON or MERCON V ATF NOTE: Automatic transmissions requiring MERCON V should only be serviced with MERCON V, or fluid from a container that is specified as a dual usage fluid: MERCON/MERCON V. NOTE: Automatic transmissions requiring MERCON can not be serviced with MERCON, MERCON V, or dual usage fluids labeled MERCON/MERCON V. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4881 Fluid - A/T: Diagrams PARK Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4882 PARK Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4883 PARK Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4884 PARK Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4885 2 ND GEAR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4886 2 ND GEAR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4887 TCC RELEASE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4888 TCC RELEASE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4889 LINE/SRV PRESSURE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4890 PARK NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4891 PARK NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4892 1ST GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4893 2ND GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4894 3RD GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4895 4TH GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4896 MANUAL 3RD GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4897 MANUAL 2ND GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4898 MANUAL 1ST GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Fluid Condition Check Fluid - A/T: Testing and Inspection 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. Perform diagnostic checks and adjustments; refer to the Diagnosis by Symptom Index. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Fluid Condition Check > Page 4901 Fluid - A/T: Testing and Inspection 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, city traffic, hot weather, or 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, shift slowly, or has signs of fluid leaking, the fluid level should be checked. 1. With the transmission in (P) Park, the engine at idle, foot pressed on the brake, move the range selector lever through each gear and allow engagement of each gear. Place the range selector lever in the Park position. 2. Wipe the fluid level indicator cap and remove the indicator. 3. Wipe the indicator with a clean cloth. 4. Install the indicator back in the filler tube until it is fully seated, then remove the indicator. The fluid level should be within the normal operating temperature range. HIGH FLUID LEVEL A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid from the vent tube and possible transmission malfunction and/or damage. If an overfill reading is indicated, refer to Transmission Fluid Drain and Refill. 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 other type of transmission fluid 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 Specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Page 4902 Fluid - A/T: Service and Repair 1. Normal maintenance requires periodic automatic transmission fluid changes. If a major service, such as a clutch, band, bearing, etc., is required, the automatic transmission fluid will also have to be removed for service. At this time, the torque converter, transmission cooler, cooler inlet tube and cooler tube must be thoroughly flushed to remove any dirt. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid as specified. - Normal Maintenance Change fluid at 48,279 km (30,000 miles). - Severe Duty/Major Overhaul Change fluid at 33,795 km (21,000 miles). 2. CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or failure. Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for the transmission code. 3. When filling a dry transmission and torque converter, refer to Specification chart for capacity. Check the fluid level. REMOVAL 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise and support vehicle on hoist. 4. Place a drain pan under the transmission fluid pan. 5. Drain transmission fluid. - Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 6. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. - Replace transmission fluid pan gasket as necessary. 7. Remove torque converter housing plug. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Page 4903 8. Remove the torque converter drain plug and drain the torque converter. - Rotate the crankshaft to access the drain plug. 9. Clean and inspect the (A) transmission fluid pan, (B) transmission fluid pan gasket and (C) magnet. 10. Flush the fluid cooler and fluid cooler lines. 11. Flush the torque converter. INSTALLATION 1. NOTE: A new torque converter drain plug must be used. Install the torque converter drain plug. 2. Install torque converter housing plug. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Page 4904 3. 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. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. 5. 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 transmission fluid pan gasket. 2 Position the transmission fluid pan. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Page 4905 6. Install bolts. 7. Lower the vehicle. 8. Connect the battery ground cable. 9. If equipped with air suspension, reactivate the system by turning on the air suspension switch. 10. NOTE: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). Fill transmission to proper fluid level. Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent fluid meeting MERCON V(R) specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair REMOVAL 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Place a drain pan under the transmission fluid pan. 5. Drain transmission fluid. - Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 6. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. 7. Pull down evenly and remove the transmission fluid filter, seal and filter kit. 8. Remove torque converter housing plug. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4909 9. Remove the torque converter drain plug and drain the torque converter. - Rotate the crankshaft to access the drain plug. 10. Clean and inspect the (A) transmission fluid pan, (B) transmission fluid pan gasket and (C) magnet. 11. Flush the fluid cooler and fluid cooler lines. 12. Flush the torque converter. INSTALLATION 1. NOTE: A new torque converter drain plug must be used. Install the torque converter drain plug. 2. Install torque converter housing plug. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4910 3. 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 serviced for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. 5. 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 transmission fluid pan gasket. 2 Position the transmission fluid pan. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4911 6. Install bolts. 7. Lower the vehicle. 8. Connect the battery ground cable. 9. If equipped with air suspension, reactivate the system by turning on the air suspension switch. 10. NOTE: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). Fill transmission to proper fluid level. Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON(R) V. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications Fluid Line/Hose: Specifications TORQUE SPECIFICATIONS Fluid Cooler Line Case Fittings ................................................................................................................................................. 20-26 Nm (15-19 ft. lbs.) Cooler Tube Nut to Case Fitting ............................................................................................................................................... 13-22 Nm (9.8-16 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 4915 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 4916 Fluid Line/Hose: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the front skid plate. 1 Remove the bolts. 2 Remove the front skid plate. 3. Remove the lower air deflector. 1 Remove the bolts. 2 Remove the lower air dam. 4. NOTE: Note the differences in the tube routing between (A) vehicles with a transmission auxiliary fluid cooler and (B) vehicles without an auxiliary fluid cooler. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 4917 For 4R70W Transmission-equipped vehicles, remove the transmission fluid cooler tube. 1 Remove the clips. 2 Disconnect the tube fittings. 3 Remove the transmission fluid cooler tube. 5. NOTE: Note the differences in the tube routing between (A) vehicles with a transmission auxiliary fluid cooler and (B) vehicles without an auxiliary fluid cooler. For E40D Transmission-equipped vehicles, remove the transmission fluid cooler tube. 1 Remove the clips. 2 Disconnect the tube fittings. 3 Remove the transmission fluid cooler tube. INSTALLATION 1. NOTE: Note the differences in the tube routing between the vehicles with a transmission auxiliary fluid cooler and the vehicles without an auxiliary fluid cooler. Install the transmission fluid cooler tube. 1 Position the transmission fluid cooler tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 4918 2 Connect the tube fittings. 3 Install the clips. 2. On E40D Transmission-equipped vehicles, connect the transmission fluid cooler tubes to the cooler bypass valve. 3. Install the lower air deflector. 1 Position the lower air dam. 2 Install the bolts. 4. Install the front skid plate. - Install the bolts. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 6. Fill the transmission fluid to the proper level and inspect for leaks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications TORQUE SPECIFICATIONS Transmission Fluid Pan Bolts ...................................................................................................................................................... 12-15 Nm (9-11 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4922 Fluid Pan: Service and Repair NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. REMOVAL 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Place a drain pan under the transmission fluid pan. 5. Drain transmission fluid. - Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 6. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. 7. Pull down evenly and remove the transmission fluid filter, seal and filter kit. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4923 8. Remove torque converter housing plug. 9. Remove the torque converter drain plug and drain the torque converter. - Rotate the crankshaft to access the drain plug. 10. Clean and inspect the (A) transmission fluid pan, (B) transmission fluid pan gasket and (C) magnet. 11. Flush the fluid cooler and fluid cooler lines. 12. Flush the torque converter. INSTALLATION 1. NOTE: A new torque converter drain plug must be used. Install the torque converter drain plug. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4924 2. Install torque converter housing plug. 3. 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 serviced for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. 5. 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 transmission fluid pan gasket. 2 Position the transmission fluid pan. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4925 6. Install bolts. 7. Lower the vehicle. 8. Connect the battery ground cable. 9. If equipped with air suspension, reactivate the system by turning on the air suspension switch. 10. NOTE: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). Fill transmission to proper fluid level. Use MERCON or MERCON V Automatic Transmission Fluid or equivalent meeting Ford specification MERCON V. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Main Regulator Booster Service Tip Fluid Pump: Technical Service Bulletins A/T - E4OD Main Regulator Booster Service Tip Article No. 97-19-20 09/15/97 TRANSMISSION - E4OD - MAIN REGULATOR BOOSTER VALVE AND SLEEVE SERVICE KIT SERVICE TIP LIGHT TRUCK: 1989-96 BRONCO 1989-97 ECONOLINE, F-150-350 SERIES, F-53 MOTORHOME CHASSIS 1997-98 EXPEDITION 1998 NAVIGATOR ISSUE: An E4OD Transmission Main Regulator Booster Valve and Sleeve Service kit has been released for service. ACTION: When servicing an E4OD transmission, inspect the main regulator booster valve and sleeve assembly for signs of wear. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify the pump is disassembled, cleaned and inspected before using this kit. 2. Refer to the appropriate Service/Workshop Manual for proper disassembly, cleaning and inspection procedures for the pump and service as required. 3. Inspect the main regulator booster valve and sleeve assembly. If the valve and sleeve show signs of wear, install kit. CAUTION: IF THE PUMP BORE THAT HOLDS THE MAIN MAIN REGULATOR BOOSTER VALVE AND SLEEVE ASSEMBLY IS DAMAGED, DO NOT USE THIS Km REPLACE THE PUMP. 4. Refer to Figure 1 for the location of the valve and sleeve. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Main Regulator Booster Service Tip > Page 4930 5. Refer to Figure 2 for orientation of the valve and sleeve in the pump. The Main Regulator Booster Valve and Sleeve kit (E9TZ-7D003-AA) contains the following: ^ One (1) Main Regulator Booster Valve ^ One (1) Main Regulator Booster Valve Sleeve ^ One (1) Instruction Sheet (I.S. 7277) PART NUMBER PART NAME E9TZ-7DO03-AA Sleeve Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000, 590000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 4931 Fluid Pump: Specifications TORQUE SPECIFICATIONS Front Pump Bolts ................................................................................................................................. ...................................... 20-26 Nm (15-19 ft. lbs.) Front Pump Support Bolts .......................................................................................................................................................... 20-26 Nm (15-19 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 4932 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 4933 Fluid Pump: Description and Operation Part 2 Of 2 The transmission uses a gerotor design front pump support and gear. The pump provides the volume of fluid needed to charge the torque converter, main control assembly, cooling system and lube system. Pump pressure is regulated by the main regulator valve. The pump is more efficient at lower engine speeds. The pump has an internal boost circuit. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 4934 Fluid Pump: Service and Repair Special Tools DISASSEMBLY Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 4935 1. Remove the No. 1 pump support thrust washer. 2. Remove the front pump support. 1 Remove the bolts. 2 Remove the front pump support. 3. NOTE: The reverse clutch cylinder seals are larger than the forward clutch cylinder rings. Remove the two (A) reverse clutch cylinder seals and the two (B) forward clutch cylinder seals. 4. Remove the (A) inner and (B) outer pump gerotor gears. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 4936 5. Carefully pry spring retainer tabs and remove the spring retainer assembly. 6. Remove the intermediate clutch piston. 7. Replace the clutch piston seals. 1 Remove the intermediate clutch piston outer seal. 2 Remove the intermediate clutch piston inner seal. 8. Remove and discard the front pump seal. ASSEMBLY Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 4937 1. Use (A) Front Pump Seal Replacer to install the (B) front pump seal assembly. 2. Install the clutch piston seals. 1 Install the intermediate clutch piston outer seal. 2 Install the intermediate clutch piston inner seal. 3. NOTE: Coat the intermediate clutch piston outer seal, intermediate clutch piston inner seal and pump body sealing area with petroleum jelly. Install the (A) intermediate clutch piston into (B) Clutch Lip Seal Protector. 4. Install the intermediate clutch piston. 1 Position the intermediate clutch piston and Clutch Lip Seal Protector onto the pump body. 2 Push the intermediate clutch piston to the bottom of the pump body bore, exerting even pressure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 4938 5. CAUTION: The piston bleed hole must be located at 12 o'clock position (towards the top of the transmission). Shift problems may occur if installed incorrectly. NOTE: The piston bleed hole is the only round hole in the pump body. Locate the piston bleed hole. 6. Install by snapping the spring retainer assembly on pump body. 7. NOTE: The flats on the inner fluid pump gear have steps that must face the pump body for ease of installing the torque converter. Install the (A) inner and (B) outer fluid pump gerotor gears. 8. NOTE: The reverse clutch cylinder seals are larger than the forward clutch cylinder seals. Install the (A) reverse clutch cylinder seal and the (B) forward clutch cylinder seals. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 4939 9. Install new front pump seal. 10. Assemble the front pump. 1 Position the pump support to the pump body assembly. 2 Install the bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) AND TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The Transmission Control Switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the Transmission Control Indicator Lamp (TCIL) when the switch is off. The TCIL indicates overdrive cancel mode activated (lamp on) and Electronic Pressure Control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Overdrive Indicator Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the transmission external control. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart: 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4946 Overdrive Indicator Lamp: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4947 Overdrive Indicator Lamp: Pinpoint Tests Test D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4948 Test D1 - D2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4949 Test D3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the (D) position. - Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise ((D) position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumb wheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications Output Shaft: Specifications TORQUE SPECIFICATIONS Output Shaft Speed (OSS) Sensor Bolt .......................................................................................................................................... 8-16 Nm (6-12 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 4959 Output Shaft, Direct Clutch Cylinder And Ring Gear Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 4960 Output Shaft: Service and Repair Special Tools Output Shaft, Direct Clutch Cylinder And Ring Gear Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 4961 Direct Clutch DISASSEMBLY 1. Remove the ring gear snap ring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 4962 2. Separate the (A) ring gear and (B) output shaft. 3. Remove the three output shaft seal rings. 4. Remove the (A) output shaft hub snap ring and the (B) output shaft hub. 5. Remove the two direct clutch seal rings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 4963 6. Remove the (A) direct clutch hub and the (B) bearing and direct clutch inner bearing support. 7. Inspect clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Replace clutch cylinder if badly scored or damaged. 8. Check fluid passage in clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and replace if necessary. Inspect check balls for freedom of movement and proper seating. 9. Check clutch release spring for distortion and cracks. Replace spring (including wave spring) if distorted or cracked. 10. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Replace all parts that are deeply scored or burred. 11. Check clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat. 12. Check clutch hub thrust surfaces for scores and clutch hub splines for wear. 13. Remove the (1) direct clutch pack retaining ring and the (2) direct clutch pack. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 4964 14. Use (A) Clutch Spring Compressor to compress the piston return spring and remove the (B) snap ring. 15. WARNING: WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. NOTE: If necessary, use regulated compressed air (207 kPa [30 psi] max pressure) to remove the clutch piston. Remove the support and spring assembly and piston. 16. Remove the inner piston seal. 17. Remove the outer piston seal. ASSEMBLY Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 4965 1. NOTE: Lubricate direct clutch piston inner seal and seal protector with petroleum jelly. Position (A) Direct Clutch Lip Seal Protector over the clutch cylinder hub and install the (B) inner piston seal. Install the seal with sealing lip facing down. 2. Install the clutch piston outer seal so that when the piston is installed the sealing lip points toward the bottom of the cylinder. 3. NOTE: Coat inner and outer direct clutch piston seals, clutch cylinder sealing area and piston inner sealing area with petroleum jelly. Use (A) Direct Clutch Lip Seal Protector to install the (B) direct clutch piston. 4. Install the piston return spring and retainer assembly. 5. Use (A) Clutch Spring Compressor to compress the piston return spring and install the (B) retaining ring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 4966 6. NOTE: Before assembly, soak new clutch discs in transmission fluid for 15 minutes. Install the (A) clutch pack and the (B) clutch pack retaining ring. Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the steel pressure plate. 7. Use a (A) feeler gauge to check the clearance between the (B) clutch pack retaining ring and the (C) pressure plate. - If the clearance is not within specifications, install the correct size retaining ring and recheck clearance. 8. Install the washer and the (B) No. 7 needle bearing on the (A) direct clutch hub and install the direct clutch hub. - Install the needle bearing with the black side up, toward direct clutch hub. NOTE: Inspect the output shaft bearing surfaces for scores. Inspect the output shaft splines for wear. Inspect all bushings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 4967 9. CAUTION: Make sure seals are lapped correctly. Internal damage may occur. Install the two direct clutch seal rings. 10. Install the output shaft hub. - Position the output shaft hub. - Install the retaining ring. 11. Install the three output shaft seal rings. 12. Install the No. 8 needle bearing on the direct clutch cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 4968 13. NOTE: Direct clutch cylinder may be installed after the output shaft ring gear is installed to the output shaft hub. Assemble the direct clutch on the output shaft. 14. Install the ring gear on the output shaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) AND TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The Transmission Control Switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the Transmission Control Indicator Lamp (TCIL) when the switch is off. The TCIL indicates overdrive cancel mode activated (lamp on) and Electronic Pressure Control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Overdrive Indicator Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the transmission external control. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart: 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4974 Overdrive Indicator Lamp: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4975 Overdrive Indicator Lamp: Pinpoint Tests Test D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4976 Test D1 - D2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4977 Test D3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission > Page 4982 Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Page 4983 Overdrive Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) AND TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The Transmission Control Switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the Transmission Control Indicator Lamp (TCIL) when the switch is off. The TCIL indicates overdrive cancel mode activated (lamp on) and Electronic Pressure Control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Overdrive Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the transmission external control. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart: 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4986 Overdrive Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4987 Overdrive Switch: Pinpoint Tests Test C1 - C2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4988 Test C2 - C3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4989 Test C3 - C4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4990 Test C4 - C5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Page 4991 Overdrive Switch: Service and Repair REMOVAL 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Diagrams > Page 4995 Planetary Gears: Service and Repair DISASSEMBLY NOTE: Inspect the outer and inner races for scores or damaged surface areas where rollers contact the races. Inspect the rollers and springs for excessive wear or damage. Inspect the spring and cage for bent or damaged spring retainers. 1. Rotate the center support counterclockwise and lift to remove the planetary gear support. 2. Remove the planetary one-way clutch. ASSEMBLY NOTE: Inspect the outer and inner races for scores or damaged surface areas where rollers contact the races. Inspect the rollers and springs for excessive wear or damage. Inspect the spring and cage for bent or damaged spring retainers. 1. Follow the disassembly procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation Pressure Regulating Solenoid: Description and Operation ELECTRONIC PRESSURE CONTROL (EPC) SOLENOID The Electronic Pressure Control (EPC) solenoid regulates transmission pressure. EPC valve pressure is used to control line pressure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 4999 Pressure Regulating Solenoid: Service and Repair REMOVAL 1. Remove the manual control lever. 2. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on locking tabs to disconnect the sensors. Disconnect the molded lead frame from the sensors. 1 Disconnect the shift solenoid SSA/SS1 and SSB/SS2. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter connector. 3. Remove the EPC solenoid. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 5000 1. Install the EPC solenoid. 2. Connect the molded lead frame to the sensors. - Connect the bulkhead inter connector. - Connect the Electronic Pressure Control (EPC) solenoid. - Connect the Torque Converter Clutch (TCC). - Connect the shift solenoid SSA/SS1 and SSB/SS2. 3. Install the manual control lever. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission > Page 5006 Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Page 5007 Overdrive Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) AND TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The Transmission Control Switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the Transmission Control Indicator Lamp (TCIL) when the switch is off. The TCIL indicates overdrive cancel mode activated (lamp on) and Electronic Pressure Control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Overdrive Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the transmission external control. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart: 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5010 Overdrive Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5011 Overdrive Switch: Pinpoint Tests Test C1 - C2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5012 Test C2 - C3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5013 Test C3 - C4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5014 Test C4 - C5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Page 5015 Overdrive Switch: Service and Repair REMOVAL 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS Transmission Range (TR) Sensor Bolts .................................................................................................................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5019 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at the left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5020 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5021 Transmission Position Switch/Sensor: Description and Operation DIGITAL TRANSMISSION RANGE (TR) SENSOR The Digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in Park and Neutral, the back-up lamp circuit in Reverse and the neutral sense circuit (4x4 only) in Neutral. The digital TR sensor also opens and closes a set of four switches that are monitored by the powertrain control module to determine the position of the manual lever (P,R,N,D,2,1). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5022 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Disconnect the digital TR electrical connector. 6. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 7. Loosen the digital TR bolts. 8. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5023 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. 9. Tighten the bolts. 10. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 11. With the manual lever in overdrive connect the shift lever control cable. 12. Install the digital TR sensor electrical connector. 13. Lower the vehicle. 14. Connect the battery ground cable. 15. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations Transmission View The Output Shaft Speed Sensor is located at the left side of the transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5027 Output Shaft Speed Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5028 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED (OSS) SENSOR The Output Shaft Speed (OSS) sensor is a magnetic pickup, located at the output shaft ring gear, that sends a signal to the Powertrain Control Module (PCM) to indicate transmission output shaft speed. The OSS is used for torque converter clutch control, shift scheduling and to determine electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Temperature Sensor, Transmission Control Transmission Temperature Sensor/Switch: Description and Operation Temperature Sensor, Transmission Control TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR The Transmission Fluid Temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermister. It sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits Torque Converter Clutch (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Temperature Sensor, Transmission Control > Page 5033 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor/Switch, A/T TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR The Transmission Fluid Temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermister. It sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits Torque Converter Clutch (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications TORQUE SPECIFICATIONS Brake Shift Interlock Solenoid Bolts ........................................................................................................................................ 7-11 Nm (63-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5038 Shift Interlock Solenoid: Service and Repair REMOVAL 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Description and Operation Shift Solenoid: Description and Operation Part 1 Of 2 Part 2 Of 2 SHIFT SOLENOID-SSA/SS1 AND SSB/SS2 Two on/off shift solenoids provide gear selection of first through fourth gears by controlling the pressure to the three shift valves. One unit containing the two shift solenoids is located in the main control valve body. The shift solenoids are two-way normally open style. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications Shifter A/T: Specifications TORQUE SPECIFICATIONS Selector Lever Arm And Support Bolts ............................................................................................................................... 12.7-17.2 Nm (10-12 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications > Page 5045 Shifter A/T: Service and Repair REMOVAL 1. Remove the ignition switch lock cylinder. 2. Remove the upper steering column shroud. 3. Remove the gearshift lever. 1 Disconnect the electrical connector. 2 Remove and discard the gearshift lever pin. 3 Remove the gearshift lever. INSTALLATION 1. NOTE: The gearshift lever pin must be replaced whenever removed. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications Selector Shaft: Specifications TORQUE SPECIFICATIONS Manual Lever Shaft Inner Nut .................................................................................................................................................... 26-37 Nm (19-27 ft. lbs.) Manual Lever Shaft Outer Nut ................................................................................................................................................... 30-35 Nm (22-26 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 5050 Selector Shaft: Service and Repair REMOVAL 1. If equipped, turn the air suspension switch off. 2. Disconnect battery ground cable. 3. Raise and support the vehicle. 4. NOTE: Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. On 4x4 vehicles, remove the front driveshaft. 1 Remove the eight front driveshaft bolts (four each end). 2 Remove the front driveshaft. 5. Drain the transmission fluid and remove the fluid pan and filter. 6. Disconnect digital TR sensor electrical connector. 7. Disconnect the transmission shift linkage. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 5051 8. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the outer manual control lever shaft nut. 2 Remove the manual control lever. 9. Remove the digital transmission range TR sensor. 1 Remove the two bolts. 2 Remove the digital TR sensor. 10. Remove the manual control valve detent lever spring. 1 Remove the bolt. 2 Remove the manual control valve detent lever spring. 11. NOTE: Use a shop cloth to protect the transmission case surface. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 5052 Remove the manual lever shaft retaining pin. 12. Remove the inner manual control lever shaft nut and slide the manual control lever shaft out of the case. 13. Remove the parking lever actuating rod. 1 Remove the manual valve detent lever. 2 Remove the parking lever actuating rod. 14. CAUTION: Use care not to damage the manual control lever shaft bore. New seal may leak. Remove the manual control lever shaft seal. INSTALLATION 1. Use (A) Shift Lever Seal Replacer to install the (B) manual control lever seal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 5053 2. Install the parking lever actuating rod. 1 Install the parking lever actuating rod. 2 Install the manual valve detent lever. 3. Install the manual control lever shaft. 1 Install the manual control lever shaft. 2 Install the inner manual control lever shaft nut. 3 Install the manual lever shaft retaining pin. 4. Install the manual valve detent lever spring. 1 Position the manual valve detent lever spring. 2 Install the manual valve detent lever spring bolt. 5. Install the digital TR sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 5054 1 Install the digital TR sensor. 2 Loosely install the bolts. NOTE: Use the Digital Transmission Range (TR) Sensor Alignment Tool for digital TR sensors. 6. NOTE: Manual shift lever must be in the neutral position. Use Digital Transmission Range (TR) Sensor Alignment Tool to align the digital TR sensor slots. 7. Tighten the bolts. 8. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 9. With manual lever in overdrive, connect the shift control cable. 10. Install digital TR sensor electrical connector. 11. Install the filter and transmission fluid pan. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 5055 12. On 4x4 vehicles, install the front driveshaft. 1 Position the front driveshaft. 2 Install the eight front driveshaft bolts (four each end). 13. Lower the vehicle. 14. Connect the battery ground cable. 15. If equipped with air suspension, reactivate the system by turning on the air suspension switch. 16. Fill the transmission with fluid and inspect for proper operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > NHTSA97V1710000 > Oct > 97 > Recall 97V171000: Shift Cable Attachment Shift Cable: Recalls Recall 97V171000: Shift Cable Attachment NHTSA CAMPAIGN ID Number: 97V171000 Component: POWER TRAIN: TRANSMISSION: AUTOMATIC: INDICATOR: LEVER: GEAR Manufacturer: FORD MOTOR COMPANY Year: 1998 Make: FORD TRUCK Model: EXPEDITION Year of Recall: '97 Type of Report: Vehicle Potential Number of Units Affected: 866000 Summary: Vehicle Description: Light duty pickup trucks and multi-purpose passenger vehicles. If the automatic transmission shift cable assembly was not fully attached to the steering column bracket, the shift cable assembly can come out of the bracket. The vehicle operator would then not be able to shift the transmission from one of the drive gear positions into the park position even though the gear shift selector would indicate "Park." The condition would not allow a disengagement of the transmission from the park position or affect proper neutral start switch operation. Unintended vehicle movement could occur if the parking brake was not set. Dealers will make the proper attachment of the transmission shift control cable to the steering column bracket and add a tie strap to that connection. Owner notification is expected to begin October 20, 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > 97S86 > Oct > 97 > Recall A/T Shift Cable Retention Technical Service Bulletin # 97S86 Date: 971001 Recall - A/T Shift Cable Retention 97S86 SAFETY RECALL Certain 1997 and 1998 F-150/250 Series Trucks, Expeditions and Certain 1998 Navigators Automatic Transmission Shift Cable Retention. Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > 97S86 > Oct > 97 > Recall A/T Shift Cable Retention > Page 5068 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. Please Note Correct all vehicles in stock before delivery. Federal law requires dealers complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. Promptly Correct Affected vehicles on the enclosed list. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > 97S86 > Oct > 97 > Recall A/T Shift Cable Retention > Page 5069 Other eligible vehicles which are brought to your dealership. Dealer-Owner Contact Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter and schedule a service date. Regional Contact Advise regional office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. Claims Submission Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Warranty And Policy Manual See Sections 5 and 6 of the ACESII Manual. Refunds See Section 3-62 of the ACESII Manual. Attachment II - Labor and Parts Information Certain 1997 and 1998 F-150/250 Series Trucks and Expeditions and Certain 1998 Navigators Automatic Transmission Shift Cable Retention. Labor Allowance Parts Requirements Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below: Stock Orders Effective immediately Normal Order Process Interim Orders Effective immediately Normal Order Process Emergency Orders On or After November 24, 1997 Normal Order Process Emergency Orders Prior to November 24, 1997 Call 1-800-325-5621 Dealer Price For latest prices, check or call your: ^ Order Processing Center ^ DOES II Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > 97S86 > Oct > 97 > Recall A/T Shift Cable Retention > Page 5070 ^ Updated Price Book Excess Stock Return Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Transmission Shift Cable Modification Affected Vehicles Certain 1997 and 1998 Model Year F-150/250 Series Trucks, Expeditions and Certain 1998 Model Year Navigators Service Procedure 1. Make sure shift cable is fully installed in steering column bracket. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > 97S86 > Oct > 97 > Recall A/T Shift Cable Retention > Page 5071 2. Install tie strap over steering column bracket and shift cable. See Figure 2. NOTE: "Cinch" tie strap tight. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > 97S86 > Oct > 97 > Recall A/T Shift Cable Retention > Page 5072 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > 97S86 > Oct > 97 > Recall A/T Shift Cable Retention > Page 5073 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > NHTSA97V171000 > Sep > 97 > Recall 97V17100: A/T Shift Cable Defect Shift Cable: Recalls Recall 97V17100: A/T Shift Cable Defect Vehicle Description: Light duty pickup trucks and multi-purpose passenger vehicles. If the automatic transmission shift cable assembly was not fully attached to the steering column bracket, the shift cable assembly can come out of the bracket. The vehicle operator would then not be able to shift the transmission from one of the drive gear positions into the park position even though the gear shift selector would indicate "Park." The condition would not allow a disengagement of the transmission from the park position or affect proper neutral start switch operation. Unintended vehicle movement could occur if the parking brake was not set. Dealers will make the proper attachment of the transmission shift control cable to the steering column bracket and add a tie strap to that connection. Owner notification is expected to begin October 20, 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1997 FORD TRUCK EXPEDITION 1997 FORD TRUCK F150 1997 FORD TRUCK F250 1998 FORD TRUCK EXPEDITION 1998 FORD TRUCK F150 1998 FORD TRUCK F250 1998 FORD TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > NHTSA97V171000 > Sep > 97 > Recall 97V171000: Shift Cable Disengages Shift Cable: Recalls Recall 97V171000: Shift Cable Disengages Year: 1997, 1998 Make: LINCOLN TRUCK, FORD TRUCK Model: NAVIGATOR, EXPEDITION, F150, F250 Year of Recall: '97 Type of Report: Vehicle Potential Number of Units Affected: 866000 Summary: Vehicle Description: Light duty pickup trucks and multi-purpose passenger vehicles. If the automatic transmission shift cable assembly was not fully attached to the steering column bracket, the shift cable assembly can come out of the bracket. The vehicle operator would then not be able to shift the transmission from one of the drive gear positions into the park position even though the gear shift selector would indicate "Park." The condition would not allow a disengagement of the transmission from the park position or affect proper neutral start switch operation. Unintended vehicle movement could occur if the parking brake was not set. Dealers will make the proper attachment of the transmission shift control cable to the steering column bracket and add a tie strap to that connection. Owner notification is expected to begin October 20, 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > NHTSA97V1710000 > Oct > 97 > Recall 97V171000: Shift Cable Attachment Shift Cable: All Technical Service Bulletins Recall 97V171000: Shift Cable Attachment NHTSA CAMPAIGN ID Number: 97V171000 Component: POWER TRAIN: TRANSMISSION: AUTOMATIC: INDICATOR: LEVER: GEAR Manufacturer: FORD MOTOR COMPANY Year: 1998 Make: FORD TRUCK Model: EXPEDITION Year of Recall: '97 Type of Report: Vehicle Potential Number of Units Affected: 866000 Summary: Vehicle Description: Light duty pickup trucks and multi-purpose passenger vehicles. If the automatic transmission shift cable assembly was not fully attached to the steering column bracket, the shift cable assembly can come out of the bracket. The vehicle operator would then not be able to shift the transmission from one of the drive gear positions into the park position even though the gear shift selector would indicate "Park." The condition would not allow a disengagement of the transmission from the park position or affect proper neutral start switch operation. Unintended vehicle movement could occur if the parking brake was not set. Dealers will make the proper attachment of the transmission shift control cable to the steering column bracket and add a tie strap to that connection. Owner notification is expected to begin October 20, 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 97S86 > Oct > 97 > Recall - A/T Shift Cable Retention Technical Service Bulletin # 97S86 Date: 971001 Recall - A/T Shift Cable Retention 97S86 SAFETY RECALL Certain 1997 and 1998 F-150/250 Series Trucks, Expeditions and Certain 1998 Navigators Automatic Transmission Shift Cable Retention. Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 97S86 > Oct > 97 > Recall - A/T Shift Cable Retention > Page 5091 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. Please Note Correct all vehicles in stock before delivery. Federal law requires dealers complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. Promptly Correct Affected vehicles on the enclosed list. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 97S86 > Oct > 97 > Recall - A/T Shift Cable Retention > Page 5092 Other eligible vehicles which are brought to your dealership. Dealer-Owner Contact Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter and schedule a service date. Regional Contact Advise regional office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. Claims Submission Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Warranty And Policy Manual See Sections 5 and 6 of the ACESII Manual. Refunds See Section 3-62 of the ACESII Manual. Attachment II - Labor and Parts Information Certain 1997 and 1998 F-150/250 Series Trucks and Expeditions and Certain 1998 Navigators Automatic Transmission Shift Cable Retention. Labor Allowance Parts Requirements Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below: Stock Orders Effective immediately Normal Order Process Interim Orders Effective immediately Normal Order Process Emergency Orders On or After November 24, 1997 Normal Order Process Emergency Orders Prior to November 24, 1997 Call 1-800-325-5621 Dealer Price For latest prices, check or call your: ^ Order Processing Center ^ DOES II Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 97S86 > Oct > 97 > Recall - A/T Shift Cable Retention > Page 5093 ^ Updated Price Book Excess Stock Return Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Transmission Shift Cable Modification Affected Vehicles Certain 1997 and 1998 Model Year F-150/250 Series Trucks, Expeditions and Certain 1998 Model Year Navigators Service Procedure 1. Make sure shift cable is fully installed in steering column bracket. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 97S86 > Oct > 97 > Recall - A/T Shift Cable Retention > Page 5094 2. Install tie strap over steering column bracket and shift cable. See Figure 2. NOTE: "Cinch" tie strap tight. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 97S86 > Oct > 97 > Recall - A/T Shift Cable Retention > Page 5095 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 97S86 > Oct > 97 > Recall - A/T Shift Cable Retention > Page 5096 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > NHTSA97V171000 > Sep > 97 > Recall 97V17100: A/T Shift Cable Defect Shift Cable: All Technical Service Bulletins Recall 97V17100: A/T Shift Cable Defect Vehicle Description: Light duty pickup trucks and multi-purpose passenger vehicles. If the automatic transmission shift cable assembly was not fully attached to the steering column bracket, the shift cable assembly can come out of the bracket. The vehicle operator would then not be able to shift the transmission from one of the drive gear positions into the park position even though the gear shift selector would indicate "Park." The condition would not allow a disengagement of the transmission from the park position or affect proper neutral start switch operation. Unintended vehicle movement could occur if the parking brake was not set. Dealers will make the proper attachment of the transmission shift control cable to the steering column bracket and add a tie strap to that connection. Owner notification is expected to begin October 20, 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1997 FORD TRUCK EXPEDITION 1997 FORD TRUCK F150 1997 FORD TRUCK F250 1998 FORD TRUCK EXPEDITION 1998 FORD TRUCK F150 1998 FORD TRUCK F250 1998 FORD TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > NHTSA97V171000 > Sep > 97 > Recall 97V171000: Shift Cable Disengages Shift Cable: All Technical Service Bulletins Recall 97V171000: Shift Cable Disengages Year: 1997, 1998 Make: LINCOLN TRUCK, FORD TRUCK Model: NAVIGATOR, EXPEDITION, F150, F250 Year of Recall: '97 Type of Report: Vehicle Potential Number of Units Affected: 866000 Summary: Vehicle Description: Light duty pickup trucks and multi-purpose passenger vehicles. If the automatic transmission shift cable assembly was not fully attached to the steering column bracket, the shift cable assembly can come out of the bracket. The vehicle operator would then not be able to shift the transmission from one of the drive gear positions into the park position even though the gear shift selector would indicate "Park." The condition would not allow a disengagement of the transmission from the park position or affect proper neutral start switch operation. Unintended vehicle movement could occur if the parking brake was not set. Dealers will make the proper attachment of the transmission shift control cable to the steering column bracket and add a tie strap to that connection. Owner notification is expected to begin October 20, 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 5105 Shift Cable: Specifications TORQUE SPECIFICATIONS Shift Cable Bracket Bolts ........................................................................................................................................................... 21-29 Nm (16-21 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 5106 Shift Cable: Adjustments 1. Place the gearshift lever in the (D) position. - Place an eight pound weight on the gearshift lever. 2. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 3. Disconnect the transmission shift cable from the manual control lever. 4. Unlock the lock tab on the transmission shift cable. 5. Place the manual control lever in the (D) position. 1 Place the manual control lever in the first gear position. 2 Move the manual control lever two detents to the (D) position. 6. Connect the transmission shift cable to the manual control lever. 7. Lock the transmission shift cable lock tab. 8. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 5107 9. Remove the eight pound weight. 10. Carefully move the manual control lever from detent to detent and compare with transmission settings. Verify that the vehicle will start in PARK or NEUTRAL and backup lamps illuminate in REVERSE. If not, Steps 1-5 must be repeated and include digital Transmission Range (TR) or Transmission Range (TR) sensor adjustment in NEUTRAL. Readjust if necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 5108 Shift Cable: Service and Repair REMOVAL 1. Disconnect the transmission shift cable from the steering column. 1 Disconnect the transmission shift cable from the transmission selector lever arm and support. 2 Disconnect the transmission shift cable from the steering column instrument panel bracket. 2. Disconnect the cable push pin. 3. Push the rubber grommet and transmission shift cable through the bulkhead. 4. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 5. Remove the transmission shift cable from the automatic transmission. 1 Disconnect the transmission shift cable from the manual control lever. 2 Depress the lock tabs to release the transmission shift cable and disconnect the transmission shift cable from the transmission shift cable bracket. 6. Remove the shift cable bracket from the transmission (4.6L). 1 Remove the bolts. 2 Remove the bracket. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 5109 7. Remove the shift cable bracket from the transmission (5.4L). 1 Remove the bolts. 2 Remove the shift cable bracket. INSTALLATION 1. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Follow the removal procedure in reverse order. Adjust the shift cable, 4R70W Transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Diagrams Sun Gear: Diagrams Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Diagrams > Page 5113 Sun Gear: Service and Repair Part 1 Of 2 Part 2 Of 2 DISASSEMBLY 1. Remove the (A) reverse sun gear assembly and the (B) No. 4 forward clutch hub bearing. 2. Remove the (A) forward clutch sun gear and the (B) No. 5 forward clutch sun gear bearing. ASSEMBLY 1. The forward clutch sun gear and reverse sun gear assembly are assembled as part of the transmission assembly procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges Torque Converter: Customer Interest A/T - Torque Converter Access Plug Dislodges Article No. 02-21-1 10/28/02 TRANSMISSION - 4R100/E4OD - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED FORD: 1989-1996 BRONCO 1989-1997 F SUPER DUTY 1989-1998 F-250 LD, F-53 MOTORHOME 1989-2003 E SERIES, F-150 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2003 EXCURSION LINCOLN: 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD ISSUE Some vehicles equipped with the E4OD/4R100 transmission may exhibit the torque converter external access dust plug dislodging and falling out during severe duty use. This may be caused by a combination of stack up tolerance, material shrinkage over time and loading being applied to the plug during usage or cleaning of the underside of the vehicle. ACTION Obtain new plug (E9TZ-7N171-A) and apply 1/4" bead of silicone sealant around entire perimeter of part and install plug into transmission case. The silicone is to be applied in the groove of the part such that when it is installed, the sealant will till any gaps between the transmission case and the plug. SERVICE PROCEDURE 1. Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4. 2. Clean transmission case casting in the area of the plug using general purpose degreaser making sure the area is free from grease and other contaminants. 3. Apply a 1/4" bead of silicone sealant F7TZ-19554-AA to plug E9TZ-7N171-A making sure that the groove in the plug is filled with silicone sealant. 4. Immediately install plug into the transmission case casting smoothing out any overflow that may occur during installation. PART NUMBER PART NAME PM-4 Motorcraft Brake Parts Cleaner E9TZ-7N171-A Plug - Converter Access F7TZ-19554-AA Ultra Silicone Sealant OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022101A Install Torque Converter 0.2 Hr. Access External Dust Plug - 1989-1996 Bronco, 1989-1997 F-150, F250LD, F-Super Duty, E-Series, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges > Page 5122 1998-2003 F-150, Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition, Navigator, 2002-2003 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 7N171 39 OASIS CODES: 504000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges Torque Converter: All Technical Service Bulletins A/T - Torque Converter Access Plug Dislodges Article No. 02-21-1 10/28/02 TRANSMISSION - 4R100/E4OD - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED FORD: 1989-1996 BRONCO 1989-1997 F SUPER DUTY 1989-1998 F-250 LD, F-53 MOTORHOME 1989-2003 E SERIES, F-150 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2003 EXCURSION LINCOLN: 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD ISSUE Some vehicles equipped with the E4OD/4R100 transmission may exhibit the torque converter external access dust plug dislodging and falling out during severe duty use. This may be caused by a combination of stack up tolerance, material shrinkage over time and loading being applied to the plug during usage or cleaning of the underside of the vehicle. ACTION Obtain new plug (E9TZ-7N171-A) and apply 1/4" bead of silicone sealant around entire perimeter of part and install plug into transmission case. The silicone is to be applied in the groove of the part such that when it is installed, the sealant will till any gaps between the transmission case and the plug. SERVICE PROCEDURE 1. Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4. 2. Clean transmission case casting in the area of the plug using general purpose degreaser making sure the area is free from grease and other contaminants. 3. Apply a 1/4" bead of silicone sealant F7TZ-19554-AA to plug E9TZ-7N171-A making sure that the groove in the plug is filled with silicone sealant. 4. Immediately install plug into the transmission case casting smoothing out any overflow that may occur during installation. PART NUMBER PART NAME PM-4 Motorcraft Brake Parts Cleaner E9TZ-7N171-A Plug - Converter Access F7TZ-19554-AA Ultra Silicone Sealant OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022101A Install Torque Converter 0.2 Hr. Access External Dust Plug - 1989-1996 Bronco, 1989-1997 F-150, F250LD, F-Super Duty, E-Series, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges > Page 5128 1998-2003 F-150, Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition, Navigator, 2002-2003 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 7N171 39 OASIS CODES: 504000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 5129 Torque Converter: Specifications GENERAL SPECIFICATIONS Stall Speed K-Factor ............................................................................................................................................... .................................................................. 165 Min ............................................................................. .......................................................................................................................................... 2200 Max .. .............................................................................................................................................................. ...................................................... 2500 End Play New or Rebuilt ...................................................................................................................................................... 0.355-1.04 mm (0.014-0.041 inch) Used ............................................................................................. ................................................................................ 0.355-1.87 (0.014-0.074 inch) TORQUE SPECIFICATIONS Torque Converter Drain Plug ..................................................................................................................................................... 28-30 Nm (21-23 ft. lbs.) Torque Converter Nuts ................................................................................ ............................................................................... 27-46 Nm (20-34 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 5130 Torque Converter: Description and Operation The torque converter transmits and multiples torque. The torque converter is a four-element device: - impeller assembly - turbine assembly - reactor assembly - clutch and damper assembly The standard torque converter components operate as follows: - Rotation of the converter housing and impeller set the fluid in motion. - The turbine reacts to the fluid motion from the impeller, transferring rotation to the geartrain through the input shaft. - The reactor redirects fluid going back into the impeller, allowing for torque multiplication. - The clutch and damper assembly dampens powertrain torsional vibration and provides a direct mechanical connection for improved efficiency. - Power is transmitted from the torque converter to the planetary gearsets and other components through the input shaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis Torque Converter: Testing and Inspection Diagnosis Prior to torque converter replacement, all Transmission Control Systems diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. Begin with the normal diagnostic procedures as follows: 1. Preliminary Inspection. 2. Know and Understand the Customer's Concern. 3. Verify the Concern-Perform the Torque Converter Clutch Operation Test. 4. Perform Diagnostic Procedures. - Run on-board diagnostics. ^ Repair all non-transmission related DTCs first. ^ Repair all transmission DTCs. ^ Rerun on-board diagnostic to verify repair. - Perform Line Pressure Test. - Perform Stall Speed Test. - Perform Diagnostic Routines. ^ Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed; diagnose and service as required before repairing the torque converter. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 5133 Torque Converter: Testing and Inspection End Play Check Special Tools 1. Insert End Play Checking Tool into the torque converter pump drive. 1 Position End Play Checking Tool. 2 Tighten the inner post until the tool is securely locked. 2. Attach Dial Indicator With Bracketry to End Play Checking Tool. - Position the dial indicator bottom on the converter pump drive hub and zero the dial. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 5134 3. Lift up on End Play Checking Tool and note the dial indicator reading. - If the reading exceeds end play limits, replace the torque converter. 4. Remove the dial indicator and tool. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 5135 Torque Converter: Testing and Inspection Leakage Checks 1. Clean the outside surface of the torque converter. 2. Install Torque Converter Leak Check Tool and Gasket into convert hub. 3. WARNING: ALWAYS FOLLOW PROPER SAFETY PROCEDURES WHILE USING PRESS. Install the torque converter with the installed leak check tool into the Arbor press. Secure the press. Apply enough force from the press to seal tool into the torque converter. 4. NOTE: Use clean dry shop air. Apply air pressure to valve on leak check tool. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 5136 5. With air pressure applied to valve, inspect for leaks at converter hub, seams and studs. A soap bubble solution may be applied around those areas to aid in diagnosis. If leaks are present, replace converter. 6. Remove air hose. Release pressure and then slowly release press. Remove converter. Remove tool. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 5137 Torque Converter: Testing and Inspection One-Way Clutch Check Special Tools 1. Insert Converter Clutch Holding Tool in one of the grooves in the stator thrust washer. 2. Install Converter Clutch Torquing Tool in the converter pump drive. 3. Use a (A) torque wrench to turn (B) Converter Clutch Torquing Tool counterclockwise hold (C) Converter Clutch Holding Tool. - The converter should lock up and hold torque. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 5138 - The torque converter one-way clutch should rotate freely in the clockwise direction. - Try the clutch for lockup and hold in at least five positions. - If the torque converter fails the lockup test torque, replace the torque converter. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 5139 Torque Converter: Testing and Inspection Diagnosis Prior to torque converter replacement, all Transmission Control Systems diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. Begin with the normal diagnostic procedures as follows: 1. Preliminary Inspection. 2. Know and Understand the Customer's Concern. 3. Verify the Concern-Perform the Torque Converter Clutch Operation Test. 4. Perform Diagnostic Procedures. - Run on-board diagnostics. ^ Repair all non-transmission related DTCs first. ^ Repair all transmission DTCs. ^ Rerun on-board diagnostic to verify repair. - Perform Line Pressure Test. - Perform Stall Speed Test. - Perform Diagnostic Routines. ^ Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed; diagnose and service as required before repairing the torque converter. End Play Check Special Tools 1. Insert End Play Checking Tool into the torque converter pump drive. 1 Position End Play Checking Tool. 2 Tighten the inner post until the tool is securely locked. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 5140 2. Attach Dial Indicator With Bracketry to End Play Checking Tool. - Position the dial indicator bottom on the converter pump drive hub and zero the dial. 3. Lift up on End Play Checking Tool and note the dial indicator reading. - If the reading exceeds end play limits, replace the torque converter. 4. Remove the dial indicator and tool. Leakage Checks 1. Clean the outside surface of the torque converter. 2. Install Torque Converter Leak Check Tool and Gasket into convert hub. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 5141 3. WARNING: ALWAYS FOLLOW PROPER SAFETY PROCEDURES WHILE USING PRESS. Install the torque converter with the installed leak check tool into the Arbor press. Secure the press. Apply enough force from the press to seal tool into the torque converter. 4. NOTE: Use clean dry shop air. Apply air pressure to valve on leak check tool. 5. With air pressure applied to valve, inspect for leaks at converter hub, seams and studs. A soap bubble solution may be applied around those areas to aid in diagnosis. If leaks are present, replace converter. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 5142 6. Remove air hose. Release pressure and then slowly release press. Remove converter. Remove tool. One-Way Clutch Check Special Tools 1. Insert Converter Clutch Holding Tool in one of the grooves in the stator thrust washer. 2. Install Converter Clutch Torquing Tool in the converter pump drive. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 5143 3. Use a (A) torque wrench to turn (B) Converter Clutch Torquing Tool counterclockwise hold (C) Converter Clutch Holding Tool. - The converter should lock up and hold torque. - The torque converter one-way clutch should rotate freely in the clockwise direction. - Try the clutch for lockup and hold in at least five positions. - If the torque converter fails the lockup test torque, replace the torque converter. Stator to Impeller Interference Check 1. NOTE: Front pump support may remain in front pump support and gear during this test. Position the front pump support with the splines up. 2. Mount (A) torque converter on the (B) front pump support with the splines on the one-way clutch inner race, engaging the mating splines of the front pump support. 3. Hold the (A) front pump support stationary and rotate the (B) torque converter counterclockwise. - The torque converter should rotate freely with no signs or scraping. - If there are signs of scraping, replace the torque converter. Stator to Turbine Interference Check 1. NOTE: Front pump support may remain in front pump support and gear during this test. Position the torque converter with the pump drive up. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Diagnosis > Page 5144 2. Install the (A) front pump support to engage the mating splines of the front pump support shaft on the (B) torque converter. 3. Install the forward clutch cylinder and shaft engaging the splines with the rear clutch hub. 4. Check for stator to turbine interference. 1 Hold the front pump support stationary. 2 Attempt to rotate the forward clutch cylinder and shaft. The turbine and torque converter clutch assemblies should rotate in both directions not exceeding maximum torque of 9.5 Nm (7 ft. lbs.) without any signs of metallic interference or scraping noise. 5. If interference exists, the stator front thrust washer may be worn, allowing the stator to hit the turbine. In such cases, the torque converter must be replaced. The converter crankshaft pilot should be checked for nicks or damaged surfaces that could cause interference when installing the torque converter into the crankshaft. Check the converter front impeller hub for nicks or sharp edges that would damage the pump seal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > Cleaning and Inspection Torque Converter: Service and Repair Cleaning and Inspection 1. If the torque converter is being replaced, continue with Substep 2 of Step 2. 2. If the torque converter is not being replaced, the following procedures must be performed: 1 The torque converter must be thoroughly cleaned. Torque converters with drain plugs can be cleaned by using Torque Converter/Oil Cooler Cleaner. - Torque converters without drain plugs can be cleaned by hand. Partially fill the torque converter using only recommended transmission fluid for the applicable transmission. Hand agitate the torque converter and then thoroughly drain the fluid. Refill the torque converter with new fluid specified for transmission, and reinstall. 2 All in-tank and auxiliary coolers must be thoroughly cleaned by forward and backward flushing. 3 All cooler lines must be thoroughly cleaned by backward and forward flushing. 4 All Cooler Bypass Valves (CBV), if equipped, must be thoroughly cleaned. 5 Perform Transmission Fluid Cooler Flow Test. 6 If the transmission cooling system fails the Transmission Fluid Cooler Flow Test, the fluid cooler, cooler bypass valve, and/or cooler lines must be replaced. 7 If the coolers are to be replaced, use only factory approved service parts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > Cleaning and Inspection > Page 5147 Torque Converter: Service and Repair Removal and Installation 1. The torque converter must be replaced if one or more of the following statements are true: - A torque converter malfunction has been determined based on complete diagnostic procedures. - Converter studs (S), Impeller Hub or Bushing are damaged. - Discoloration of the torque (due to overheating). - The torque converter is found to be out of specification when performing one of the following torque converter checks: One-Way Clutch Check - End Play Check - Stator to Turbine Interference Check - Stator to Impeller Interference Check - Torque Converter Leak Check - 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 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > Cleaning and Inspection > Page 5148 Torque Converter: Service and Repair Flushing NOTE: When the transmission has been repaired for internal damage the torque converter must be cleaned using a mechanically agitated cleaner. 1. Use Torque Converter/Oil Cooler Cleaner to clean and flush the torque converter. 2. After flushing, drain the remainder of the solvent through the converter access plug. 3. Add 1.9 liter (2 qt.) of clean transmission fluid to the converter and agitate by hand. 4. Thoroughly drain the solution through the converter access plug. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TORQUE SPECIFICATIONS TCC Solenoid Bolt ............................................................................................................................... .................................. 9-11 Nm (80-100 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5152 Torque Converter Clutch Solenoid: Description and Operation Part 1 Of 2 Part 2 Of 2 The Torque Converter Clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Transmission Cooler: Customer Interest A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 5161 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 5162 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 5163 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips Transmission Cooler: All Technical Service Bulletins A/T - Cooler Flushing Service Tips Article No. 03-14-8 07/21/03 TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003 WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER This article supersedes TSB 00-1-5. ISSUE The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher"). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher" uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are 2 issues with this method: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 5169 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 5170 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Transmission Cooler: All Technical Service Bulletins A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 5175 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 5176 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 5177 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips Transmission Cooler: All Technical Service Bulletins A/T - Cooler Flushing Service Tips Article No. 03-14-8 07/21/03 TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003 WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER This article supersedes TSB 00-1-5. ISSUE The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher"). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher" uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are 2 issues with this method: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 5183 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 5184 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 5185 Transmission Cooler: Description and Operation All vehicles with automatic transmissions are equipped with an integral transmission fluid cooler. The integral transmission fluid cooler is contained inside of the radiator outlet tank and cannot be repaired separately. Some vehicles are equipped with an optional auxiliary transmission fluid cooler that is mounted in front of the radiator. In operation, transmission fluid travels from the transmission to the auxiliary transmission fluid cooler, if equipped, to the integral transmission fluid cooler then back to the transmission. The integral transmission fluid cooler transfers heat from the transmission fluid to the engine coolant. The auxiliary transmission fluid cooler transfers heat from the transmission fluid to the outside air. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Transmission Cooler: Initial Inspection and Diagnostic Overview When fluid leakage is found at the any of the transmission fluid cooling components, the component must be replaced. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5188 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5189 Transmission Cooler: Component Tests and General Diagnostics CAUTION: Whenever a transmission has been disassembled to replace worn or damaged parts the Cooler Bypass Valve (CBV), all transmission fluid coolers (in tank and auxiliary) and transmission fluid cooler lines must be cleaned and backflushed. Use the 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 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. NOTE: The transmission linkage/cable adjustment, fluid level and line pressure must be within specification before performing this test. 1. Remove fluid level indicator from fluid filler tube. 2. Place funnel in fluid filler tube. 3. Raise the vehicle on a hoist and place suitable safety stands under the vehicle. 4. Remove the cooler return line (rear 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. 7. Start the engine and run it at idle with the transmission in Neutral position. 8. Once a steady flow of fluid (without air bubbles) is observed, remove the hose from the funnel and place the hose in a measuring container for 30 seconds. After 30 seconds place the hose back into the funnel and turn the engine off. Measure the amount of fluid in the container. If adequate flow was observed, approximately 1.0 liter 1.057 quarts) will be in the measuring container; the test is now 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 outline fitting (front fitting) on the transmission case. 10. Repeat steps 7 and 8. If flow is now approximately 1 liter (1 quart) in 30 seconds, refer to transmission removal for cleaning and backflushing. If the flow is still not approximately 1 liter (1 quart) in 30 seconds, service the pump and/or converter. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Backflush/Cleaning Transmission Cooler: Service and Repair Backflush/Cleaning 1. Conduct backflushing with a Torque Converter/Oil Cooler Cleaner. Test your equipment to make sure that a vigorous fluid flow is present before proceeding. Replace the system filter if flow is weak or contaminated. 2. 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. 1 Connect the cleaner tank pressure line to the steel transmission cooler return line (longest line). 2 Connect a tank return hose to the steel transmission cooler pressure line (shorter line). Place the outlet end of this hose in the solvent tank reservoir. 3. Turn on solvent pump and allow the solvent to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in cooler system). 4. Switch off the solvent pump and disconnect the solvent pressure hose from the transmission cooler return line. 5. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all solvent is removed. 6. Remove the rubber return hose from the remaining steel cooler line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Backflush/Cleaning > Page 5192 Transmission Cooler: Service and Repair Removal and Installation REMOVAL 1. Remove the front skid plate. 1 Remove the bolts. 2 Remove the front skid plate. 2. Place a drain pan under the auxiliary transmission fluid cooler. 3. Remove the auxiliary transmission fluid cooler. 1 Disconnect the auxiliary transmission fluid cooler tubes. 2 Remove the bolts. 3 Remove the auxiliary transmission fluid cooler. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Backflush/Cleaning > Page 5193 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5201 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5202 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5203 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5204 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5205 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5206 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5207 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5208 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5209 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5210 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5211 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5212 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5213 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5214 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5215 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5216 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5217 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5218 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5219 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5220 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5221 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5222 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5223 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5224 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5225 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5226 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5227 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5228 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5229 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5230 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5231 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5232 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5233 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5234 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5235 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5236 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5237 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5238 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5239 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5240 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5241 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5242 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5243 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5244 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5245 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5246 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5247 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5248 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5249 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5250 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5251 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5252 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5253 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5254 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5255 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5256 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5257 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5258 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5259 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5260 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5261 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5262 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5263 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5264 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5265 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5266 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5267 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5268 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5269 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5270 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5271 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5272 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5273 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5274 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5275 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5276 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5277 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5278 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5279 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5280 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5281 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5282 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5283 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5284 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5285 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5286 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5287 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5288 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5289 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5290 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5291 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5292 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5293 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 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. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5294 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 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. 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 the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5295 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Page 5296 Transmission Mount: Specifications TORQUE SPECIFICATIONS Transmission Mount Nuts ........................................................................................................................................................ 98-132 Nm (73-97 ft. lbs.) Transmission Mount Bolts ....................................................................................................................................................... 87-110 Nm (64-81 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Page 5297 Transmission Mount: Service and Repair REMOVAL 1. If equipped, turn air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original positions. Remove the rear driveshaft. 1 Remove the four bolts. 2 Remove the driveshaft. 5. Use High-Lift Jack to support the transmission. 6. Remove the nuts. 7. Remove the bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Page 5298 8. Remove the transmission crossmember. 1 Remove the bolts. 2 Remove the transmission crossmember. 9. Remove the rear support insulator. INSTALLATION 1. Install the rear support insulator. 2. Install the transmission crossmember. 1 Position the transmission crossmember. 2 Install the bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Page 5299 3. Install the transmission crossmember bolts. 4. Remove the High-Lift Jack. 1 Install the nuts. 5. Install the drive shaft. 6. Lower the vehicle. 7. Connect the battery ground cable. 8. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS Transmission Range (TR) Sensor Bolts .................................................................................................................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5303 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at the left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5304 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5305 Transmission Position Switch/Sensor: Description and Operation DIGITAL TRANSMISSION RANGE (TR) SENSOR The Digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in Park and Neutral, the back-up lamp circuit in Reverse and the neutral sense circuit (4x4 only) in Neutral. The digital TR sensor also opens and closes a set of four switches that are monitored by the powertrain control module to determine the position of the manual lever (P,R,N,D,2,1). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5306 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Disconnect the digital TR electrical connector. 6. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 7. Loosen the digital TR bolts. 8. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5307 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. 9. Tighten the bolts. 10. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 11. With the manual lever in overdrive connect the shift lever control cable. 12. Install the digital TR sensor electrical connector. 13. Lower the vehicle. 14. Connect the battery ground cable. 15. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations Transmission View The Output Shaft Speed Sensor is located at the left side of the transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5311 Output Shaft Speed Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5312 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED (OSS) SENSOR The Output Shaft Speed (OSS) sensor is a magnetic pickup, located at the output shaft ring gear, that sends a signal to the Powertrain Control Module (PCM) to indicate transmission output shaft speed. The OSS is used for torque converter clutch control, shift scheduling and to determine electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Temperature Sensor, Transmission Control Transmission Temperature Sensor/Switch: Description and Operation Temperature Sensor, Transmission Control TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR The Transmission Fluid Temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermister. It sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits Torque Converter Clutch (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Temperature Sensor, Transmission Control > Page 5317 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor/Switch, A/T TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR The Transmission Fluid Temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermister. It sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits Torque Converter Clutch (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 98-9-20 > May > 98 > A/T - E4OD 4-1 Downshift During Forced 4-2 Downshift Valve Body: Customer Interest A/T - E4OD 4-1 Downshift During Forced 4-2 Downshift Article No. 98-9-20 05/11/98 TRANSMISSION - E4OD - DOWNSHIFT DURING A FORCED 4-2 DOWNSHIFT BETWEEN 88-105 KM/H (55-65 MPH) - VEHICLES BUILT THROUGH 12/22/97 LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE Some vehicles may experience a 4-1 downshift when performing a forced 4-2 downshift (kickdown) between 88-105 km/h (55-65 mph) causing the engine rpm to increase higher than expected. This may be caused by internal leakage of fluid between the hydraulic circuits in the transmission case worm trail between the separator plate gasket and transmission case. ACTION Perform normal diagnostics as outlined in the appropriate Workshop Manual. If the concern is still present, replace the separator plate and gaskets. Refer to the Application Chart below and the appropriate Workshop Manual for replacement procedures. PART NUMBER PART NAME F8UZ-7A008-CA Separator Plate F81Z-7A008-EA Separator Plate F81Z-7C155-AA Gasket F81Z-7D100-AB Gasket OTHER APPLICABLE ARTICLES: 98-9-21 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 98O92OA Replace Separator Plate 2.1 Hrs. And Gasket DEALER CODING CONDITION BASIC PART NO. CODE 7A008, 7D100 42 OASIS CODES: 502000, 504000, 590000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage Valve Body: All Technical Service Bulletins A/T - Main Controls/Separator Plate/Gaskets Usage Article No. 98-16-8 08/17/98 TRANSMISSION - E4OD/4R100 - 1989-99 - MAIN CONTROLS, SEPARATOR PLATES AND SEPARATOR PLATE GASKETS USAGE CHART LIGHT TRUCK: 1989-96 BRONCO, F-150 1989-97 F SUPER DUTY, F-250 HD 1989-98 ECONOLINE, F-250 LD, F-35O 1997-98 EXPEDITION, F-150 1998 NAVIGATOR 1999 SUPER DUTY F SERIES Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage > Page 5331 This TSB article is being republished in its entirety to revise Figure 1. ISSUE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage > Page 5332 The Chart has been developed to assist in showing the complexity and compatibility of main controls, separator plates, and plate gaskets used for E4OD/4R100 transmissions. ACTION Refer to the Usage Chart for information showing the compatibility of main controls, separator plates, and plate gaskets. This TSB should not be used in place of the Parts Catalog. NOTE TO VERIFY CORRECT GASKET USAGE, REFER TO FIGURE 1 TO IDENTIFY THE SEPARATOR PLATE I.D. NOTCHES. THEN REFER TO THE CHART TO SEE WHICH GASKETS ARE COMPATIBLE WITH THE MAIN CONTROLS AND SEPARATOR PLATES BEING USED. CAUTION MIXING COMPONENTS OTHER THAN THOSE LISTED MAY CAUSE SHIFT CONCERNS AND/OR DAMAGE TO THE TRANSMISSION. REFER TO THE PARTS CATALOG FOR PROPER USAGE BY MODEL AND YEAR. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-9-21 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000, 590000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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: > 98-9-20 > May > 98 > A/T - E4OD 4-1 Downshift During Forced 4-2 Downshift Valve Body: All Technical Service Bulletins A/T - E4OD 4-1 Downshift During Forced 4-2 Downshift Article No. 98-9-20 05/11/98 TRANSMISSION - E4OD - DOWNSHIFT DURING A FORCED 4-2 DOWNSHIFT BETWEEN 88-105 KM/H (55-65 MPH) - VEHICLES BUILT THROUGH 12/22/97 LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE Some vehicles may experience a 4-1 downshift when performing a forced 4-2 downshift (kickdown) between 88-105 km/h (55-65 mph) causing the engine rpm to increase higher than expected. This may be caused by internal leakage of fluid between the hydraulic circuits in the transmission case worm trail between the separator plate gasket and transmission case. ACTION Perform normal diagnostics as outlined in the appropriate Workshop Manual. If the concern is still present, replace the separator plate and gaskets. Refer to the Application Chart below and the appropriate Workshop Manual for replacement procedures. PART NUMBER PART NAME F8UZ-7A008-CA Separator Plate F81Z-7A008-EA Separator Plate F81Z-7C155-AA Gasket F81Z-7D100-AB Gasket OTHER APPLICABLE ARTICLES: 98-9-21 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 98O92OA Replace Separator Plate 2.1 Hrs. And Gasket DEALER CODING CONDITION BASIC PART NO. CODE 7A008, 7D100 42 OASIS CODES: 502000, 504000, 590000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage Valve Body: All Technical Service Bulletins A/T - Main Controls/Separator Plate/Gaskets Usage Article No. 98-16-8 08/17/98 TRANSMISSION - E4OD/4R100 - 1989-99 - MAIN CONTROLS, SEPARATOR PLATES AND SEPARATOR PLATE GASKETS USAGE CHART LIGHT TRUCK: 1989-96 BRONCO, F-150 1989-97 F SUPER DUTY, F-250 HD 1989-98 ECONOLINE, F-250 LD, F-35O 1997-98 EXPEDITION, F-150 1998 NAVIGATOR 1999 SUPER DUTY F SERIES Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage > Page 5342 This TSB article is being republished in its entirety to revise Figure 1. ISSUE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage > Page 5343 The Chart has been developed to assist in showing the complexity and compatibility of main controls, separator plates, and plate gaskets used for E4OD/4R100 transmissions. ACTION Refer to the Usage Chart for information showing the compatibility of main controls, separator plates, and plate gaskets. This TSB should not be used in place of the Parts Catalog. NOTE TO VERIFY CORRECT GASKET USAGE, REFER TO FIGURE 1 TO IDENTIFY THE SEPARATOR PLATE I.D. NOTCHES. THEN REFER TO THE CHART TO SEE WHICH GASKETS ARE COMPATIBLE WITH THE MAIN CONTROLS AND SEPARATOR PLATES BEING USED. CAUTION MIXING COMPONENTS OTHER THAN THOSE LISTED MAY CAUSE SHIFT CONCERNS AND/OR DAMAGE TO THE TRANSMISSION. REFER TO THE PARTS CATALOG FOR PROPER USAGE BY MODEL AND YEAR. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-9-21 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000, 590000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5344 Valve Body: Specifications TORQUE SPECIFICATIONS Main Control Valve Body Bolts ............................................................................................................................................... 9-11 Nm (80-98 inch lbs.) Main Control Valve Body Cover Plate Bolts ........................................................................................................................... 9-11 Nm (80-98 inch lbs.) Main Control Valve Body Separator Plate Bolts ...................................................................................................................... 9-11 Nm (80-98 inch lbs.) Manual Control Valve Detent Lever Spring Bolt ..................................................................................................................... 9-11 Nm (80-98 inch lbs.) Valve Body Reinforcement Plates ............................................................................................................................................ 9-11 Nm (80-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5345 Valve Body: Diagrams Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5346 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5347 Valve Body: Description and Operation The main control valve body houses three electronic solenoids: Two shift solenoids - Torque Converter Clutch Solenoid (TCC solenoid) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation Valve Body: Service and Repair Removal and Installation REMOVAL 1. If equipped, turn the air suspension switch OFF. 2. Disconnect battery ground cable. 3. Raise and support the vehicle. 4. Drain transmission fluid and remove the transmission fluid pan and filter. 5. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the sensors. Disconnect the molded lead frame from the sensors. Disconnect the molded lead frame from the sensors. 1 Disconnect the shift solenoid SSA/SS1 and SSB/SS2. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the electronic pressure control (EPC) solenoid. 4 Disconnect the bulkhead inter connector. 6. Remove the shift solenoid and the Torque Converter Clutch (TCC) solenoid. 1 Remove the bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5350 2 Remove the shift solenoid and the Torque Converter Clutch (TCC) solenoid. 7. Remove the manual control valve detent lever spring. 1 Remove the bolt. 2 Remove the manual control valve detent lever spring. 8. Remove the 23 valve body to case bolts. 9. Remove the main control valve body. INSTALLATION 1. NOTE: Make sure that the drive pin of the manual valve detent lever assembly engages the manual valve in the proper location prior to installing the bolts. Position the main control valve body gasket and main control valve body using the two alignment bolts as a guide. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5351 2. NOTE: The main control valve body bolts will be tightened in later steps. Loosely install the bolts. 3. NOTE: The main control valve body bolts will be tightened in later steps. Loosely install the bolts. 4. 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5352 5. Tighten the main control valve body bolts in the sequence shown. 6. Install the shift solenoid and the Torque Converter Clutch (TCC) solenoid. 1 Install the shift solenoid and the Torque Converter Clutch (TCC) solenoid. 2 Install the bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5353 7. Connect the molded lead frame to the sensors. - Connect the bulkhead inter connector. - Connect the Electronic Pressure Control (EPC) solenoid. - Connect the Torque Converter Clutch (TCC). - Connect the shift solenoid SSA/SS1 and SSB/SS2. 8. CAUTION: If installing a new filter, and the grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore. NOTE: If transmission is being serviced for a contamination-related failure, use a new filter and seal. Replace fluid filter and seal as required. 9. Position the (B) pan magnet into the (A) transmission fluid pan. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5354 10. NOTE: The pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan. 1 Position the transmission fluid pan gasket. 2 Position the transmission fluid pan. 11. Install the bolts. 12. Lower the vehicle. 13. Connect the battery ground cable. 14. If equipped with air suspension, reactive the system by turning on the air suspension switch. 15. Fill the transmission with fluid and check for proper operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5355 Valve Body: Service and Repair Disassembly and Assembly Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5356 Part 2 Of 2 DISASSEMBLY 1. Remove the Torque Converter Clutch Solenoid (TCC solenoid) and the shift solenoid. 1 Remove the bolt. 2 Remove the shift solenoid. 3 Remove the torque converter clutch solenoid. 2. Remove the three reinforcement plates. 1 Remove the ten main control valve body separator plate bolts. 2 Remove the three reinforcement plates. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5357 3. Remove the separator plate and discard the gaskets. 4. NOTE: Note the location of the eight coasting booster valve shuttle balls for assembly. Remove the eight coasting booster valve shuttle balls. 5. Remove the converter drain back valve and solenoid pressure supply screen. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5358 6. Remove the main control valve body cover plate. 1 Remove the thirteen bolts. 2 Remove the valve body cover plate and gasket. ASSEMBLY 1. NOTE: Before beginning assembly, perform/inspect the following: When building up subassemblies and assembling the transmission, ALWAYS use new gaskets and seals. All fasteners must be tightened to the torque specification indicated. When building up subassemblies, each component part should be lubricated with clean transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case. Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly. Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to machined surfaces. Install the valve body cover plate. 1 Position the valve body cover plate gasket and cover plate. 2 Install the two guide pin bolts. 3 Install the valve body cover plate bolts. 2. Tighten the valve body cover plate bolts in the sequence shown. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5359 3. Install the eight coasting booster valve shuttle balls. 4. Install the converter drain back valve and solenoid pressure supply screen. 5. Install the separator plate and gaskets. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5360 6. Install the three reinforcement plates. 1 Position the three reinforcement plates. 2 Install the bolts. 7. NOTE: Inspect the shift solenoid O-rings and TCC solenoid O-rings for damage. Install the shift solenoid. 1 Position the shift solenoid. 2 Position the TCC solenoid. 3 Install the bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Technical Service Bulletins > Customer Interest: > 99-14-3 > Jul > 99 > Front Differential Moaning Noise In 2WD Mode Carrier Side Gears: Customer Interest Front Differential - Moaning Noise In 2WD Mode Article No. 99-14-3 07/12/99 ^ NOISE - "MOANING" FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE - VEHICLES BUILT THROUGH 4/15/1999 ^ AXLE - "MOANING" NOISE FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE VEHICLES BUILT THROUGH 4/15/1999 FORD: 1997-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-1999 NAVIGATOR ISSUE Some 4X4 vehicles built with center disconnect front axles may exhibit a "moaning" noise from the front differential while operating in 4X2 mode. The noise goes away when operating in 4X4 mode. This may be caused by the front differential side gears. ACTION Replace the front differential side gears with revised gears and replace the front differential pinion gears with revised gears. Refer to the following text for details. For vehicles that exhibit a front differential moan in 4X2 mode that goes away in 4X4 mode, replace both front axle side gears and both front axle pinion gears. Replace any worn or damaged pinion thrust washers and side gear washers. Refer to Section 205-03 of the appropriate model/year Workshop Manual for removal and installation procedures. PART NUMBER PART NAME XL3Z-4236-M Side Gears (2 Per Box) XL3Z-4215-M Pinion Gears (2 Per Box) DOAZ-4230-B Pinion Thrust washer C90Z-4228-B Side Gear washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991403A Replace Axle Side Gears 1.4 Hrs. And Pinion Gears DEALER CODING CONDITION BASIC PART NO. CODE 4235 42 OASIS CODES: 509000, 597997, 702100 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-14-3 > Jul > 99 > Front Differential - Moaning Noise In 2WD Mode Carrier Side Gears: All Technical Service Bulletins Front Differential - Moaning Noise In 2WD Mode Article No. 99-14-3 07/12/99 ^ NOISE - "MOANING" FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE - VEHICLES BUILT THROUGH 4/15/1999 ^ AXLE - "MOANING" NOISE FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE VEHICLES BUILT THROUGH 4/15/1999 FORD: 1997-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-1999 NAVIGATOR ISSUE Some 4X4 vehicles built with center disconnect front axles may exhibit a "moaning" noise from the front differential while operating in 4X2 mode. The noise goes away when operating in 4X4 mode. This may be caused by the front differential side gears. ACTION Replace the front differential side gears with revised gears and replace the front differential pinion gears with revised gears. Refer to the following text for details. For vehicles that exhibit a front differential moan in 4X2 mode that goes away in 4X4 mode, replace both front axle side gears and both front axle pinion gears. Replace any worn or damaged pinion thrust washers and side gear washers. Refer to Section 205-03 of the appropriate model/year Workshop Manual for removal and installation procedures. PART NUMBER PART NAME XL3Z-4236-M Side Gears (2 Per Box) XL3Z-4215-M Pinion Gears (2 Per Box) DOAZ-4230-B Pinion Thrust washer C90Z-4228-B Side Gear washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991403A Replace Axle Side Gears 1.4 Hrs. And Pinion Gears DEALER CODING CONDITION BASIC PART NO. CODE 4235 42 OASIS CODES: 509000, 597997, 702100 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Technical Service Bulletins > All Other Service Bulletins for Carrier Side Gears: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Technical Service Bulletins > All Other Service Bulletins for Carrier Side Gears: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 5381 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Technical Service Bulletins > All Other Service Bulletins for Carrier Side Gears: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 5382 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Technical Service Bulletins > All Other Service Bulletins for Carrier Side Gears: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 5388 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Technical Service Bulletins > All Other Service Bulletins for Carrier Side Gears: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 5389 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Front Drive Axle Differential Case: Specifications Front Drive Axle GENERAL SPECIFICATIONS Differential Case Maximum Runout .............................................................................................................................................. 0.076 mm (0.003 inch) Housing Spreader Adapter Thread Engagement mm (inch) ......................................................................................................................... 12.77 (0.500) TORQUE SPECIFICATIONS Axle Housing Cover Bolts ......................................................................................................................................................... 27-37 Nm (20-27 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Front Drive Axle > Page 5394 Differential Case: Specifications 8.8 Inch Ring Gear TORQUE SPECIFICATIONS Rear Axle Housing Vent .............................................................................................................................................................. 11-24 Nm (8-18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Front Drive Axle > Page 5395 Differential Case: Specifications 9.75 Inch Ring Gear GENERAL SPECIFICATIONS Differential Case Maximum Runout ............................................................................................................................................................. 0.076 (0.003) TORQUE SPECIFICATIONS Rear Axle Housing Vent .............................................................................................................................................................. 11-24 Nm (8-18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 5396 Differential Case: Testing and Inspection Special Tools Front Differential Case Runout Check 1. Remove the front axle assembly. 2. Remove the axle housing cover. 1 Remove the drain plug. 2 Drain the differential lubricant. 3 Remove the bolts. 4 Remove the axle housing cover. 3. CAUTION: Fixture mounting bolts must have a minimum thread engagement in the carrier. Install the Bench Mounted Holding Fixture. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 5397 4. Install the Dial Indicator with Bracketry. 5. Check the ring gear runout. 1 Rotate the differential. 2 Check and record the reading. 6. Refer to the specification to compare actual ring gear runout to verify it is within specifications. NOTE: If the ring gear runout check exceeds specification, the cause may be a warped ring gear, a damaged differential case or loss of differential bearing preload. To determine the cause of the excessive runout, proceed with the following steps. 7. Remove the pinion gear. 8. Remove the spreader. 9. Position the differential case with the differential bearing cups in the front axle housing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 5398 10. Install the differential bearing shim on the left side. 11. Install the LH bearing cap. 1 Position the bearing cap. 2 Install the bolts finger-tight. 12. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim can be assembled with a slight drag feel. 13. Tighten the bearing cap bolts. 1 Install the RH bearing cap and bolts. 2 Tighten the four bearing cap bolts. 14. Rotate the assembly to ensure free rotation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 5399 15. Install the Dial Indicator with Bracketry. 16. NOTE: See the specification for maximum ring gear runout. Check the ring gear runout. 1 Rotate the differential. 2 Check and record the reading. 17. If the runout is within specification, the original out-of-specification runout was caused by insufficient bearing preload. If the runout exceeds the specification, go to Step 18. 18. Remove the bearing caps. 1 Remove the bolts. 2 Remove the bearing caps. 19. Remove the differential case from the housing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 5400 20. Remove the differential ring gear. - Remove the ten differential ring gear bolts. - Use a drift punch to separate the differential ring gear from the differential case. 21. Install the differential case in the housing without the ring gear. 1 Position the differential case. 2 Install the bearing caps. 3 Install the bearing cap bolts. 22. Position the Dial Indicator with Bracketry. 1 Rotate the differential case to ensure the differential bearings are properly seated. 2 Position the Dial Indicator with Bracketry. 23. NOTE: See the specification for maximum differential case runout. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 5401 Measure the differential case runout without the ring gear. 1 Rotate the differential case. 2 Check and note the differential case runout. 24. Remove the bearing caps. 1 Remove the bearing cap bolts. 2 Remove the bearing caps. 25. Remove the differential case from the housing. NOTE: If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, replace both the differential case and the differential bearings. 26. Assemble the Pinion and Carrier Bearing Puller. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 5402 27. Use the 2-Jaw Puller and the Step Tool to remove the differential bearings. 28. NOTE: Press against the differential bearing inner cone only. Install the new differential bearings. 1 Position the appropriate differential bearing (RH or LH). 2 Use the appropriate press to install the differential bearing. Repeat the procedure for the other differential bearing. 29. Install the differential case in the housing without the ring gear. 1 Position the differential case. 2 Install the bearing caps. 3 Install the bearing cap bolts. 30. Position the Dial Indicator with Bracketry. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 5403 1 Rotate the differential case to ensure differential bearings are properly seated. 2 Position the Dial Indicator with Bracketry. 31. NOTE: See the specification for maximum differential case runout. If runout is now within specification, use new differential bearings for assembly. If runout is still excessive, the differential case is damaged and should be replaced. Recheck runout with the new differential case and differential bearings. 1 Rotate the differential case. 2 Recheck and note the differential case runout. 32. Remove the bearing caps bolts. 33. Remove the differential case from the housing. 1 Remove the bearing caps. 2 Remove the differential case. 34. Install the pinion gear and the ring gear. 35. Install the front drive axle assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly Differential Case: Service and Repair Disassembly and Assembly Special Tools Special Tools Special Tools DISASSEMBLY 1. Remove the differential case from the front drive axle assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5406 2. Remove the differential ring gear. - Remove the ten differential ring gear bolts. - Use a drift punch to separate the differential ring gear from the differential case. 3. Remove the differential pinion shaft lock bolt from the differential case. 4. Remove the differential pinion shaft. 5. Remove the differential pinion thrust washers. 1 Rotate the differential pinion gears to the differential case window and remove. 2 Remove the differential pinion thrust washers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5407 6. Remove the differential side gears and the side gear thrust washers. ASSEMBLY 1. Use Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL meeting Ford specification WSP-M2C201-A to lubricate the differential side gear thrust washers and the differential side gear journals. Position the differential side gear thrust washers on the differential side gears. 2. Position the differential side gears. 3. Use Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL meeting Ford specification WSP-M2C201-A to lubricate the differential pinion thrust washers and the differential pinion gears and assemble. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5408 4. Engage the differential pinion gears opposite the differential side gears. 5. Rotate the differential pinion gears to align the differential pinion shaft bore. 6. Insert the differential pinion shaft. 7. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Thread lock and Sealer EOAZ-19554-AA or equivalent meeting Ford specifications WSK-M2G315-A5 and ESE-M4G204-A2 prior to installation. Install a new differential pinion shaft lock bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5409 8. Install the ring gear. - Position and then start three ring gear bolts to align the holes in the ring gear and the differential case. - Use an appropriate press to install the ring gear. 9. Install the remaining ring gear bolts. 10. Install the differential case into the front drive axle housing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5410 Differential Case: Service and Repair 8.8 Inch Ring Gear Removal and Installation Special Tools Special Tools REMOVAL 1. Remove the axle housing cover and drain the axle. 2. Remove the axle shafts. 3. Wipe the lubricant from the internal working parts and visually inspect the parts for wear or damage. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5411 4. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears. 5. NOTE: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear backface runout. Position Dial Indicator with Bracketry and inspect ring gear backlash and ring gear backface runout. 6. CAUTION: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions. Mark the bearing cap position before removal. Loosen the differential case. 1 Remove the four bearing cap bolts. 2 Remove the two bearing caps. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5412 7. WARNING: BE CAREFUL NOT TO ALLOW THE DIFFERENTIAL CASE TO FALL. CAUTION: Place a wood block between the pry bar and the axle housing to protect the machined surface from damage. Use the pry bar and the wood block to remove the differential case from the rear axle housing. 8. Remove the 10 ring gear bolts. 9. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Insert a punch in the bolt holes and drive off the ring gear and, if necessary, the anti-lock speed sensor ring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5413 10. Install the differential case. - Position the differential case assembly, including the bearing clips and shims, in the rear axle housing. Install the differential bearing caps and the differential bearing cap bolts. 11. Position the Dial Indicator with Bracketry. 1 Rotate the differential case to ensure the differential bearings are properly seated. 2 Position the Dial Indicator with Bracketry. 12. NOTE: If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, replace both the differential case and the differential bearings. Measure the differential case runout without the ring gear. 1 Rotate the differential case. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5414 2 Check and note the differential case runout. 13. Remove the differential case from the rear axle housing and remove the differential bearings using the 2-Jaw Puller for Differential Case Bearings and the Step Plate Adapter. 14. Use the Differential Side Bearing Replacer to install the new differential bearings on the differential case. 15. Install the differential case. Position the differential case assembly, including the bearing caps, bolts and shims in the rear axle housing. Tighten bearing caps to specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5415 16. Measure the differential case runout without the ring gear. - Check the case runout again with the new differential bearings. If the runout is now within the specification shown, use the new differential bearings for assembly. If the runout is still excessive, the differential case is damaged and must be replaced. INSTALLATION 1. Press a new anti-lock speed sensor ring, if removed, and the ring gear on the differential case. 2. Install the ring gear bolts. Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to ring gear bolts. 3. With pinion depth set and pinion installed, place the differential case in the carrier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5416 4. Install a (nominal) shim on the left side. 5. CAUTION: Mark the position of the bearing caps, as arrows may not be visible. The bearing caps must be installed in their identical locations and positions. NOTE: Apply pressure toward the left side to make sure the left bearing cup is seated. Install the left bearing cap and loosely install the bearing cap bolts. 6. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand. 7. Install the right side bearing cap and tighten the left side and right side bolts to specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5417 8. Rotate the differential case to make sure it rotates freely. 9. Use the Dial Indicator with Bracketry to measure the ring gear backlash. - If the backlash is within specification, go to Step 14. The specification shown is the full allowable range. For the preferred range, refer to Specifications. - If a zero backlash condition occurs, go to Step 10. - If the backlash is not within specification, go to Step 11. 10. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication. Check the backlash Repeat Step 9. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5418 11. To increase or decrease the backlash, remove the bearing caps and install a thicker shim or a thinner shim as shown. - If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount. 12. Rotate the differential several times to make sure the differential bearings are properly seated. 13. Use the Dial Indicator with Bracketry to recheck the backlash. - If the backlash is within specification, go to Step 14. If the backlash is not within specification, repeat Step 9. - The specification shown is the full allowable range. For the preferred range, refer to Specifications. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5419 14. Remove the bearing caps and bolts. - To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration. - Use a shim driver to ensure the differential bearing shims are fully seated and the assembly turns freely. 15. CAUTION: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions. Install the bearing caps and bearing cap bolts. 16. Use the Dial Indicator with Bracketry to recheck the backlash. - For further adjustments. 17. Install the axle shafts. 18. Install the driveshaft. 19. Install the axle housing cover and refill the rear axle with specified lubricant. Conventional Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5420 Special Tools DISASSEMBLY 1. Remove the differential case. 2. Remove the 10 ring gear bolts. 3. Insert a punch in the bolt holes and drive the ring gear off. 4. NOTE: The speed sensor ring cannot be reused once removed. Remove the speed sensor ring, if required. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5421 5. If required, use the 2-Jaw Puller for Differential Case Bearings and Step Plate Adapter to remove the differential bearing. 6. Remove the differential pinion shaft lock bolt. 7. Remove the differential pinion shaft. 8. Rotate and remove the differential pinion gears and differential pinion thrust washers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5422 9. Remove the differential side gears and the differential pinion thrust washers. ASSEMBLY 1. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B meeting Ford specification WSL-M2C192-A to lubricate the differential side gear thrust washers and the differential side gear journals. Position the differential side gear thrust washers on the differential side gears. 2. Position the differential side gears. 3. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B meeting Ford specification WSL-M2C192-A to lubricate the differential pinion thrust washers and the differential pinion gears and assemble. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5423 4. Engage the differential pinion gears opposite the differential side gears. 5. Rotate the differential pinion gears to align with the differential pinion shaft bore. 6. Insert the differential pinion shaft. - Align the hole in the differential pinion shaft with the hole in the differential case. 7. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specifications WSK-M2G315-A5 and ESE-M4G204-A2 prior to installation. Install a new differential pinion shaft lock bolt and tighten finger-tight. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5424 8. Use Differential Side Bearing Replacer to install the new differential bearings on the differential case. 9. Align the notches for the anti-lock ring. 10. Press the new anti-lock speed sensor ring and the ring gear on the differential case. 11. Install the ring gear bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5425 - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to ring gear bolts. 12. Install the differential case. Traction-LOK Special Tools Special Tools DISASSEMBLY 1. Remove the differential case. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5426 2. Remove the 10 ring gear bolts. 3. Insert a punch in the bolt holes and drive the ring gear off. 4. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Remove the speed sensor ring, if required. 5. Use the 2-Jaw Puller for Differential Case Bearings and Step Plate Adapter to remove the differential bearing. - Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5427 6. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft. 7. WARNING: DUE TO THE SPRING TENSION, CARE MUST BE USED WHEN REMOVING THE DIFFERENTIAL CLUTCH SPRING. Remove the differential clutch spring. 8. Remove the differential gears. 1 Remove the two differential pinion gears. 2 Remove the two differential side gears. 3 Remove the two differential pinion thrust washers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5428 9. CAUTION: Keep differential clutch packs in order. Do not mix. They must be reassembled in the same sequence. Remove the differential clutch packs and differential side gears and tag them "right" and "left" with the shim. Clean and inspect the remaining parts of the differential case for wear or damage and replace parts as necessary. 10. CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only. Clean and inspect the differential clutch packs for wear and replace parts as necessary. ASSEMBLY 1. CAUTION: 118 ml (4 oz) of the specified Ford Friction Modifier must be used in the axle. Prelubricate each steel clutch plate and soak all friction plates with additive Ford Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least l5 minutes. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5429 2. NOTE: Do not mix the differential clutch packs or shims from one side with the other. Assemble the differential clutch packs (without the shims) on the respective differential side gears. 3. CAUTION: Make sure the proper mandrel is used with a Traction-Lok(R) Clutch Gauge. Place the base portion of Traction-Lok(R) Clutch Gauge in a vise. Install the differential clutch pack and differential side gear (without the shim) on the gauge. Refer to the tool chart for the correct mandrel. 4. Position the Traction-Lok(R) Clutch Gauge on top of the differential clutch pack. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5430 5. Install Top Traction-Lok(R) Clutch Gauge over the disc and differential clutch pack. 6. Install the nut of the gauge over the top and base stud. 7. Use a feeler gauge and select the thickest blade that will enter between the tool and the differential clutch pack. - The reading will be the thickness of the new clutch shim. 8. Remove Traction-Lok(R) Clutch Gauge from the clutch pack and side gear assembly. 9. Install shims on the clutch pack and side gear assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5431 10. Install the differential side gear in the differential case. 11. Install the differential pinion gears with differential pinion thrust washers in the differential case. 12. Install the differential clutch spring, using a soft-faced hammer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5432 13. Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight. 14. Use the Differential Side Bearing Replacer to install the differential bearing on the differential case. Repeat for the other side. 15. NOTE: Start two of the ring gear bolts through the differential case and into the ring gear to make sure the ring gear bolt holes align with the differential case bolt holes properly. Install the anti-lock speed sensor ring by aligning the tab on the anti-lock speed sensor ring with the slot on the differential case. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5433 16. Press the new anti-lock speed sensor ring and the ring gear on the differential case. 17. Install the ring gear bolts. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. 18. Install the differential case. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5434 Differential Case: Service and Repair 9.75 Inch Ring Gear Removal and Installation Special Tools Special Tools REMOVAL 1. Remove the axle housing cover and drain the axle. 2. Remove the axle shafts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5435 3. Mark the driveshaft flange and the driveshaft rear axle companion flange for correct alignment during installation. 4. Wipe the lubricant from the internal working parts, and visually inspect the parts for wear or damage. 5. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears. 6. NOTE: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear backface runout. Position the Dial Indicator with Bracketry, and inspect ring gear backlash and ring gear backface runout. 7. CAUTION: The bearing caps must be installed in their identical locations and positions. Mark each bearing cap before removal. Loosen the differential case. 1 Remove the bearing cap bolts. 2 Remove the bearing caps. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5436 8. WARNING: BE CAREFUL NOT TO ALLOW THE DIFFERENTIAL CASE TO FALL. CAUTION: Place a wood block between the pry bar and the axle housing to protect the machined surface from damage. Use the pry bar and the wood block to remove the differential case from the carrier. 9. Remove the ring gear bolts. 10. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Insert a punch in the bolt holes. Drive off the ring gear and, if necessary, the anti-lock speed sensor ring. 11. Install the differential case. 1 Position the differential case assembly, including bearing clips and shims, in the carrier. 2 Install the differential bearing caps. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5437 3 Install the differential bearing cap bolts. 12. Position the Dial Indicator with Bracketry. 1 Rotate the differential case to make sure the differential bearings are properly seated. 2 Position the Dial Indicator with Bracketry. 13. NOTE: If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, replace both the differential case and the differential bearings. Measure the differential case runout without the ring gear. 1 Rotate the differential case. 2 Check and note the differential case runout. 14. Remove the differential case from the rear axle housing, and remove the differential bearings using the 2-Jaw Puller for Differential Case Bearings and the Step Plate Adapter. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5438 15. Use the Differential Bearing Cone Replacer to install the new differential bearings on the differential case. 16. Measure the differential case runout without the ring gear. - Check the case runout again with the new differential bearings. If the runout is now at 0.076 mm (0.003 inch), use the new differential bearings for assembly. If the runout is still excessive, the differential case is damaged and must be replaced. INSTALLATION 1. Press the ring gear and, if removed, a new anti-lock speed sensor on the differential case. 2. Install the ring gear bolts. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5439 3. With pinion depth set and the pinion installed, place the differential case in the rear axle housing. 4. Install a (nominal) shim on the left side. 5. CAUTION: The bearing caps must be installed in their identical locations and positions. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated. Install the left bearing cap, and loosely install the bearing cap bolts. 6. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5440 7. Install the right side bearing cap, and tighten the bolts. 8. Rotate the differential case to make sure it rotates freely. 9. Use the Dial Indicator with Bracketry to measure ring gear backlash. - If the backlash is within specification, go to Step 15. The specification shown is the full allowable range. For the preferred range, refer to Specifications. - If a zero backlash condition occurs, go to Step 10. - If the backlash is not within specification, go to Step 11. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5441 10. If a zero backlash condition occurs, add a 0.50-mm (0.020-inch) shim to the RH side and subtract 0.50 mm (0.020 inch) from the LH side to allow backlash indication. Check backlash. Repeat Step 9. 11. To increase or decrease backlash, remove the bearing caps, and install a thicker shim and a thinner shim as shown. - If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount. 12. Install the bearing caps and bearing cap bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5442 13. Rotate the differential several times to make sure the differential bearings are properly seated. 14. Use the Dial Indicator with Bracketry to recheck the backlash. - If backlash is within specification, go to Step 15. If not, repeat Step 9. - The specification shown is the full allowable range. For the preferred range, refer to Specifications. 15. Remove the bearing caps and bolts. - To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration. - Use the Shim Driver to ensure the differential bearing shims are fully seated and the assembly turns freely. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5443 16. Install the bearing caps and bearing cap bolts. 17. Use the Dial Indicator with Bracketry to verify the backlash. 18. Install the axle shafts. 19. Install the axle housing cover, and refill the rear axle with specified lubricant. 20. Install the driveshaft. Conventional - Differential Case and Ring Gear Special Tools DISASSEMBLY 1. Remove the differential case. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5444 2. Remove the ring gear bolts. 3. Insert a punch in the bolt holes and drive the ring gear off. 4. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Remove the anti-lock speed sensor ring. 5. If required, remove the differential bearings with the 2-Jaw Puller for Differential Case Bearings and the Step Plate Adapter. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5445 6. Remove the differential pinion shaft lock bolt and the differential pinion shaft. 7. Rotate and remove the differential pinion gears and differential pinion thrust washers. 8. Remove the differential side gears and the differential side gear thrust washers. ASSEMBLY 1. Position the differential side gear thrust washers on the differential side gears. - Use Motorcraft Synthetic Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A to lubricate the differential side gear thrust washers and the differential side gear journals. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5446 2. Position the differential side gears. 3. Assemble the differential pinion thrust washers and the differential pinion gears. - Lubricate with Motorcraft Synthetic Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 4. Engage the differential pinion gears opposite the differential side gears. 5. Install the differential bearings, using the Differential Bearing Cone Replacer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5447 6. Rotate the differential pinion gears to align the differential pinion shaft bore. 7. Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight. 8. Press the new anti-lock speed sensor ring and the ring gear on the differential case. - The notch on the differential case flange and the notch on the anti-lock speed sensor ring must be aligned. 9. Install the ring gear bolts and tighten. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. 10. Install the differential case. Traction-Lok - Differential Case and Rear Gear Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5448 Special Tools Special Tools DISASSEMBLY Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5449 1. Remove the differential case. 2. NOTE: The differential bearings need not be removed to overhaul the Ford limited slip differential. If bearing removal is required, use the 2-Jaw Puller for Differential Case Bearings and the Step Plate Adapter. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft. If required, remove the ring gear and anti-lock speed sensor ring. 3. Install the Traction-Lok(R) Torque Tool in a suitable vise. 4. Install the differential case on the tool. 5. Install the Step Plate Adapter in the bottom side gear bore. Apply a small amount of grease to the centering hole of the Step Plate Adapter. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5450 6. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw. Tighten the hex-head screw until contact is made with the Step Plate Adapter. 7. NOTE: The dowel bar is used to keep the nut from turning when the forcing screw is tightened. Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gear away from the differential pinion gears. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5451 8. WARNING: KEEP FINGERS/HANDS AWAY FROM PINION GEARS WHEN ROTATING THE DIFFERENTIAL CASE WITH THE DIFFERENTIAL ROTATING TOOL. NOTE: Differential pinion thrust washers cannot be removed independently of the differential pinion gears and so must be removed simultaneously with the differential pinion gears. Insert the Limited Slip Differential Rotating Tool in the pinion shaft bore, and turn the differential case to "walk" the differential pinion gears and differential pinion thrust washers out to the differential case windows. 9. Remove the differential pinion gears and differential pinion thrust washers. 10. Remove the differential side gears and differential clutch packs,and tag them RIGHT and LEFT with the shim. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5452 11. CAUTION: When separating the clutch plates and clutch discs, note the sequence in which they are disassembled. They must be reassembled in the same sequence. CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only. Separate the differential clutch discs and clutch plates for cleaning and inspection. Refer to the disassembled view of the limited slip differential case. ASSEMBLY 1. Prelubricate each steel clutch plate and soak all friction plates in Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes. 2. NOTE: Do not mix the differential clutch packs or shims from one side with the other. NOTE: The Belleville spring is a dished plate. Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5453 3. NOTE: Use the Traction-Lok(R) Clutch Gauge Mandrel for the procedure. Refer to the Special Tool(s) Chart. Clamp the bolt head of the Traction-Lok(R) Clutch Gauge in a vise. Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge. 4. Position the Traction-Lok(R) Clutch Gauge on top of the differential clutch pack. 5. Install the Traction-Lok Clutch Gauge over the disc and differential clutch pack. 6. Install the nut of the gauge over the top and base stud. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5454 7. Use the Feeler Gauge and select the thickest blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim. Select the correct shim size, and remove the Traction-Lok(R) Clutch Gauge. 8. Place the shim and Belleville spring on the differential clutch pack. - The dished or concave side of the Belleville spring must face up and against the thrust face of the differential case. [] Refer to the exploded view. 9. Insert the differential clutch packs with shims and Belleville springs and differential side gears into the differential case. - Hold the upper clutch pack and side gear assembly in place to prevent it from falling out of the differential case. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5455 10. NOTE: Apply a small amount of grease to the step plate bore. NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened. Assemble the forcing screw, nut and step plate to the differential case. 1 Position the Step Plate Adapter in the bottom side gear bore. 2 Position the nut in the top side gear bore and hold it in place. 3 Install the hex-head screw and tighten it two turns after it contacts the bottom step plate. 11. NOTE: Prelubricate both sides of the differential pinion thrust washers with Motorcraft Synthetic Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. NOTE: Make sure the differential pinion gears are 180° apart so they will align correctly with the pinion shaft bore. Position the differential pinion gears and differential pinion thrust washers in the window of the differential case so they mesh with the differential side gear teeth. 12. WARNING: KEEP FINGERS/HANDS AWAY FROM PINION GEARS WHEN ROTATING THE DIFFERENTIAL CASE WITH THE DIFFERENTIAL ROTATING TOOL. NOTE: It will probably be necessary to loosen or tighten the forcing screw to allow the differential pinion gears and differential side gears to rotate. Insert the rotating handle into the pinion shaft bore, and turn the differential case. This will cause the differential pinion gears to engage the differential side gears and "walk" into the differential case. Rotate the differential case until the pinion mating shaft holes are lined up exactly with the holes in the differential pinion gears. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5456 13. Loosen the forcing screw, and remove the step plate and nut from the side gear bores. Install the differential pinion shaft in the differential case. - Install a new differential pinion shaft lock bolt finger-tight. 14. Replace the differential bearings, if removed, using the Differential Bearing Cone Replacer. 15. Using a press, install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the retaining bolts. - The notch on the differential case flange and the notch on the anti-lock speed sensor ring must be aligned. 16. Install the differential case. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > Customer Interest for Differential Clutch: > 98-11-7 > Jun > 98 > Rear Axle Chattering On Turns Or Cornering Differential Clutch: Customer Interest Rear Axle - Chattering On Turns Or Cornering Article No. 98-11-7 06/08/98 ^ NOISE - "CHATTERING" NOISE FROM REAR AXLE HEARD ON TURNS OR WHEN CORNERING - VEHICLES WITH LIMITED SLIP AXLE ^ AXLE - LIMITED SLIP - REAR AXLE "CHATTERING" NOISE ON TURNS OR WHEN CORNERING LIGHT TRUCK: 1997-98 E-150, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE A "chattering" noise from the rear axle may be heard when turning or cornering. This may be due to differentials containing clutch packs that have been gauged too tightly. ACTION Install new Traction-Lok Clutch Pack Kit. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Confirm axle chatter with road test. 2. Once axle chatter has been confirmed, remove and discard old clutch packs, shims and Belleville springs. Refer to the appropriate Workshop Manual for details. NOTE SUBTRACT 0.25 mm (0.010") FROM FEELER GAUGE READING TAKEN DURING SHIM SELECTION USING SERVICE TOOLS AND PROCEDURES INDICATED ON INSTRUCTION SHEETS PACKAGED WITH KITS. 3. Install Clutch Pack Kit F75Z-4947-AA for 9.75-inch ring gear Tracktion-Lok axles and Kit F75Z-4947-AB for 10.25-inch ring gear Traction-Lok axles. For ring gear size and differential type, see embossed metal tag attached to rear axle cover. Refer to the appropriate Workshop Manual for details. PART NUMBER PART NAME F75Z-4947-AA Clutch Pack Kit (9.75" Ring Gear) F75Z-4947-AB Clutch Pack Kit (10.25" Ring Gear) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981107A Install Clutch Pack (Drum 2.2 Hrs. Brake Applications) 981107B Install Clutch Pack (Disc 2.4 Hrs. Brake Applications Without 981107C Install Clutch Pack (Disc 2.5 Hrs. Brake Applications With Air Suspension) DEALER CODING CONDITION BASIC PART NO. CODE 4026 56 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > Customer Interest for Differential Clutch: > 98-11-7 > Jun > 98 > Rear Axle Chattering On Turns Or Cornering > Page 5465 OASIS CODES: 509000, 510000, 597997, 702000, 702200 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Clutch: > 98-11-7 > Jun > 98 > Rear Axle - Chattering On Turns Or Cornering Differential Clutch: All Technical Service Bulletins Rear Axle - Chattering On Turns Or Cornering Article No. 98-11-7 06/08/98 ^ NOISE - "CHATTERING" NOISE FROM REAR AXLE HEARD ON TURNS OR WHEN CORNERING - VEHICLES WITH LIMITED SLIP AXLE ^ AXLE - LIMITED SLIP - REAR AXLE "CHATTERING" NOISE ON TURNS OR WHEN CORNERING LIGHT TRUCK: 1997-98 E-150, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE A "chattering" noise from the rear axle may be heard when turning or cornering. This may be due to differentials containing clutch packs that have been gauged too tightly. ACTION Install new Traction-Lok Clutch Pack Kit. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Confirm axle chatter with road test. 2. Once axle chatter has been confirmed, remove and discard old clutch packs, shims and Belleville springs. Refer to the appropriate Workshop Manual for details. NOTE SUBTRACT 0.25 mm (0.010") FROM FEELER GAUGE READING TAKEN DURING SHIM SELECTION USING SERVICE TOOLS AND PROCEDURES INDICATED ON INSTRUCTION SHEETS PACKAGED WITH KITS. 3. Install Clutch Pack Kit F75Z-4947-AA for 9.75-inch ring gear Tracktion-Lok axles and Kit F75Z-4947-AB for 10.25-inch ring gear Traction-Lok axles. For ring gear size and differential type, see embossed metal tag attached to rear axle cover. Refer to the appropriate Workshop Manual for details. PART NUMBER PART NAME F75Z-4947-AA Clutch Pack Kit (9.75" Ring Gear) F75Z-4947-AB Clutch Pack Kit (10.25" Ring Gear) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981107A Install Clutch Pack (Drum 2.2 Hrs. Brake Applications) 981107B Install Clutch Pack (Disc 2.4 Hrs. Brake Applications Without 981107C Install Clutch Pack (Disc 2.5 Hrs. Brake Applications With Air Suspension) DEALER CODING CONDITION BASIC PART NO. CODE 4026 56 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Clutch: > 98-11-7 > Jun > 98 > Rear Axle - Chattering On Turns Or Cornering > Page 5471 OASIS CODES: 509000, 510000, 597997, 702000, 702200 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Front Drive Axle Differential Cover: Specifications Front Drive Axle GENERAL SPECIFICATIONS Differential Cover Bushing Gap mm (inch) .................................................................................................................................................... 1.93 (0.076) TORQUE SPECIFICATIONS Differential Cover Bushing Bolts ............................................................................................................................................. 77-103 Nm (57-75 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Front Drive Axle > Page 5476 Differential Cover: Specifications 8.8 Inch Ring Gear TORQUE SPECIFICATIONS Axle Housing Cover Bolts ......................................................................................................................................................... 38-52 Nm (28-38 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Front Drive Axle > Page 5477 Differential Cover: Specifications 9.75 Inch Ring Gear TORQUE SPECIFICATIONS Axle Housing Cover Bolts ......................................................................................................................................................... 38-52 Nm (28-38 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear Differential Cover: Service and Repair 8.8 Inch Ring Gear REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Remove the axle housing cover. 1 Remove the 10 axle housing cover bolts and drain the lubricant from the rear axle housing. 2 Remove the axle housing cover. INSTALLATION 1. CAUTION: Make sure the machined surfaces on both the rear axle housing and the axle housing cover are clean and free of oil before installing the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination. Clean the gasket mating surface of the rear axle and the axle housing cover. 2. Apply a new continuous bead of sealant to the axle housing cover. - Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A. 3. NOTE: The axle housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5480 allow one hour before filling with lubricant to make sure the silicone sealant has properly cured. Install the axle housing cover. 1 Install the axle housing cover. 2 Install the 10 axle housing cover bolts. 4. NOTE: Service refill capacities are determined by filling the rear axle with the specified lubricant 6.4-14.3 mm (1/4-9/16 inch) below the bottom of the filler hole. Fill the rear axle with 2.37 liters (5 pints) of Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A and install the filler plug. For Traction-Lok(R) axles, first fill the rear axle with 118 ml (4 oz) of specified Ford Friction Modifier. 5. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5481 Differential Cover: Service and Repair 9.75 Inch Ring Gear REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Remove the axle housing cover. 1 Remove the 12 axle housing cover bolts, and drain the lubricant from the rear axle housing. 2 Remove the axle housing cover. INSTALLATION 1. CAUTION: Make sure the machined surfaces on both the rear axle housing and the axle housing cover are clean and free of oil before applying the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination. Clean the gasket mating surface of the rear axle and the axle housing cover. 2. Apply a new, continuous bead of sealant to the axle housing cover. - Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A. 3. NOTE: The axle housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow 1 hour before filling with lubricant to ensure the silicone sealant has properly cured. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5482 Install the axle housing cover and tighten the axle housing cover bolts. 4. NOTE: Service refill capacities are determined by filling the rear axle with the specified lubricant to the specified level below the bottom of the filler hole. Fill the rear axle with specified lubricant, and install the filler plug. For Traction-Lok(R) axles, first fill the rear axle with 118 ml (4 ounces) of specified Ford Additive Friction Modifier. 5. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Specifications > Front Drive Axle Differential Axle Housing: Specifications Front Drive Axle TORQUE SPECIFICATIONS Right Axle Tube Bushing Bolt ................................................................................................................................................. 77-103 Nm (57-75 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Specifications > Front Drive Axle > Page 5487 Differential Axle Housing: Specifications 8.8 Inch Ring Gear TORQUE SPECIFICATIONS Rear Spring Plate Nuts ............................................................................................................................................................. 98-132 Nm (73-97 ft. lbs.) Traction-Lok(R) Clutch Gauge Nut ................................................................................................................................................. 6.7 Nm (60 inch lbs.) Track Bar Retainer Bolt ..................................................................................................................................................... 170-230 Nm (125-169 ft. lbs.) Bounce Bumper Retainer Bolts .................................................................................................................................................. 34-46 Nm (25-33 ft. lbs.) Driver Handle ......................................................................................................... .......................................................................... 2.2 Nm (20 inch lbs.) Initial Minimum Breakaway Torque (Traction-Lok(R) ........................................................................................................................ 27 Nm (20 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Specifications > Front Drive Axle > Page 5488 Differential Axle Housing: Specifications 9.75 Inch Ring Gear TORQUE SPECIFICATIONS Rear Spring Plate Nuts ............................................................................................................................................................. 98-132 Nm (73-97 ft. lbs.) Minimum Breakaway Torque-(Traction-Lok(R)) ................................................................................................................................. 27 Nm (20 ft. lbs.) Driver Handle ............................................................................................................................... .................................................... 2.2 Nm (20 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Diagrams > Front Drive Axle Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Diagrams > Front Drive Axle > Page 5491 Differential Axle Housing: Diagrams 8.8 Inch Ring Gear Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Diagrams > Front Drive Axle > Page 5492 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Diagrams > Front Drive Axle > Page 5493 Differential Axle Housing: Diagrams 9.75 Inch Ring Gear Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Diagrams > Front Drive Axle > Page 5494 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle Differential Axle Housing: Service and Repair Rear Drive Axle Air Suspension REMOVAL 1. WARNING: DO NOT REMOVE AN AIR SPRING UNDER ANY CIRCUMSTANCES WHEN THERE IS PRESSURE IN THE AIR SPRING. DO NOT REMOVE ANY COMPONENTS SUPPORTING AN AIR SPRING WITHOUT EITHER EXHAUSTING THE AIR OR PROVIDING SUPPORT FOR THE AIR SPRING TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Remove the rear wheel and tire assembly. 3. Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. 4. Remove the four driveshaft bolts and disconnect the driveshaft. - Wire the driveshaft aside. 5. Disconnect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5497 6. Disconnect the parking brake cable and conduit from the rear wheel disc brake adapter. - Repeat for the other side. 7. Remove the rear disc brake caliper and position it out of the way - Repeat for the other side. 8. CAUTION: Whenever the O-ring is removed, install a new one. Remove the O-ring. Repeat for the other side. 9. Remove the rear disc brake rotor. - Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5498 10. Remove the rear stabilizer bar retainer bolts. - Repeat for the other side. 11. Loosen the rear stabilizer bar links and bushings. 12. Disconnect the air suspension height sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5499 13. WARNING: USE EXTRA STRAPS TO SECURE THE REAR AXLE TO THE JACK. Install a suitable hydraulic jack under the rear axle housing. 14. Remove the rear axle tracking bar assembly retainer bolt and position the rear axle tracking bar out of the way. 15. Remove the jounce bumper. - Repeat for the other side. 16. Remove the rear suspension upper front arm and bushing retainer bolt. - Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5500 17. Remove the rear suspension arm retainer bolt and position the rear suspension arm and bushing out of the way. - Repeat for the other side. 18. Remove the lower shock absorber retainer bolt. - Repeat for the other side. 19. Remove the rear axle housing vent hose. 20. CAUTION: Watch for obstructions. Lower the rear axle on the jack until it is clear of the vehicle. INSTALLATION 1. WARNING: USE EXTRA STRAPS TO SECURE THE REAR AXLE TO THE JACK. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5501 Raise the rear axle into place using a suitable hydraulic jack. 2. Position the rear suspension upper front arm and bushing and install the retainer bolt. - Repeat for the other side. 3. Position the rear suspension arm and bushing and install the retainer bolt. - Repeat for the other side. 4. Raise the rear axle with the jack until the rear suspension arm and bushings are parallel to the ground and install the rear stabilizer bar retainer bolts. Repeat for the other side. 5. Tighten the rear suspension arm and bushing. - Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5502 6. Tighten the rear suspension upper front arm and bushing retainer bolt. - Repeat for the other side. 7. Position the rear axle tracking bar in the bracket and install the retainer bolt. Tighten it to specification. 8. Connect the rear axle housing vent hose. 9. Install and tighten the rear stabilizer bar retainer bolts. - Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5503 10. Tighten the rear stabilizer bar links and bushings. 11. Tighten the shock absorber retainer bolts. - Repeat for the other side. 12. Remove the jack. 13. Install the driveshaft and tighten the retainer capscrews. 14. Lower the vehicle partially. 15. Install the jounce bumper retainer bolts and tighten to specification. - Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5504 16. Install the parking brake rear cable and conduit. - Repeat for the other side. 17. Install the rear disc brake rotor. - Repeat for the other side. 18. Install a new O-ring. - Repeat for the other side. 19. Install the rear disc brake caliper. - Repeat for the other side. 20. Install the wheels and tires. 1 Position the tire and wheel assembly. 2 Install the lug nuts and lower the vehicle. 3 Tighten the lug nuts. 4 Install the center cap. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5505 21. Connect the air suspension height sensor. 22. Connect the electrical connector at the anti-lock speed sensor. 23. Lower the vehicle. 24. Turn on the air suspension control switch. Coil Suspension REMOVAL 1. Raise and support the vehicle. 2. Remove the rear wheel and tire assembly. 3. Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. 4. Remove the four driveshaft bolts and disconnect the driveshaft and wire it out of the way. - Wire the driveshaft aside. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5506 5. Disconnect the electrical connector at the anti-lock speed sensor. 6. Disconnect the parking brake cable and conduit from the rear wheel disc brake adapter. - Repeat for the other side. 7. Remove the rear disc brake caliper and position it out of the way. - Repeat for the other side. 8. CAUTION: Whenever the O-ring is removed, install a new one. Remove the O-ring. Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5507 9. Remove the rear disc brake rotor. - Repeat for the other side. 10. Remove the rear stabilizer bar retainer bolts. - Repeat for the other side. 11. Loosen the rear stabilizer bar links and bushings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5508 12. Install jack stands beneath the rear axle and lower the vehicle onto the jack stands. - Place a third jack stand under the front of the rear axle housing. 13. Remove the rear axle tracking bar assembly retainer bolt and position the rear axle tracking bar out of the way. 14. Remove the jounce bumper. - Repeat for the other side. 15. Remove the rear suspension upper front arm and bushing retainer bolt. - Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5509 16. Remove the rear suspension arm and bushing retainer bolt and position the rear suspension arm and bushing out of the way. - Repeat for the other side. 17. Remove the lower shock absorber retainer bolt. - Repeat for the other side. 18. Remove the rear axle housing vent hose. 19. CAUTION: This step should be performed with an assistant to keep the axle clear of obstructions while the vehicle is being raised. Raise the vehicle clear of the rear axle. 20. Remove both rear springs. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5510 1. CAUTION: The following step should be performed with the aid of an assistant. Position the rear axle on jack stands under the vehicle. Place a third jack stand under the front of the carrier so that it points slightly upward. This will allow the control arms to clear the rear axle when the vehicle is lowered. 2. Lower the vehicle onto the rear axle. 3. Position the rear suspension upper front arm and bushing and install the retainer bolt. - Repeat for the other side. 4. Position the rear suspension arm and bushing and install the retainer bolt. - Repeat for the other side. 5. Raise the vehicle and position a suitable hydraulic jack under the rear axle differential carrier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5511 6. Raise the rear axle with the jack until the rear suspension arm and bushing are parallel to the ground and install the lower shock absorber retainer bolts. 7. Tighten the rear suspension arm and bushing. - Repeat for the other side. 8. Tighten the rear suspension upper front arm and bushing retainer bolt. - Repeat for the other side. 9. Lower the rear axle until it is hanging freely. 10. Install both rear springs. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5512 11. Raise the rear axle and position the rear axle tracking bar in the bracket and install the retainer bolt. Tighten it to specification. 12. Connect the rear axle housing vent hose. 13. Install and tighten the rear stabilizer bar retainer bolts on both sides. 14. Tighten the rear stabilizer bar links and bushings securely on both sides. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5513 15. Tighten the lower shock absorber retainer bolts. 16. Lower the jack and remove it. 17. Install the driveshaft and tighten the retainer capscrews. 18. Lower the vehicle partially. 19. Install the jounce bumper retainer bolts and tighten to specification. - Repeat for the other side. 20. Install the parking brake rear cable and conduit. - Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5514 21. Install the rear disc brake rotor. - Repeat for the other side. 22. Install a new O-ring. - Repeat for the other side. 23. Install the rear disc brake caliper. 24. Install the wheels and tires. 1 Position the tire and wheel assembly. 2 Install the lug nuts and lower the vehicle. 3 Tighten the lug nuts. 4 Install the center cap. 25. Connect the electrical connector at the anti-lock speed sensor. 26. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5515 Air Suspension REMOVAL 1. WARNING: DO NOT REMOVE AN AIR SPRING UNDER ANY CIRCUMSTANCES WHEN THERE IS PRESSURE IN THE AIR SPRING. DO NOT REMOVE ANY COMPONENTS SUPPORTING AN AIR SPRING WITHOUT EITHER EXHAUSTING THE AIR OR PROVIDING SUPPORT FOR THE AIR SPRING TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Remove the rear wheel and tire assembly. 3. Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. 4. Remove the four driveshaft bolts, and disconnect the driveshaft. - Wire the driveshaft aside. 5. Disconnect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5516 6. Disconnect the parking brake rear cable and conduit from the rear wheel disc brake adapter. - Repeat for the other side. 7. Remove the rear disc brake caliper, and position it out of the way. - Repeat for the other side. 8. CAUTION: Whenever the O-ring is removed, install a new one. Remove the O-ring. Repeat for the other side. 9. Remove the rear disc brake rotor. - Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5517 10. Remove the rear stabilizer bar retainer bolts. - Repeat for the other side. 11. Loosen the rear stabilizer bar links and bushings. 12. Disconnect the air suspension height sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5518 13. WARNING: USE EXTRA STRAPS TO SECURE THE REAR AXLE TO THE JACK. Install a suitable hydraulic jack under the rear axle housing. 14. Remove the rear axle Lacking bar assembly retainer bolt, and position the rear axle tracking bar out of the way. 15. Remove the jounce bumper. - Repeat for the other side. 16. Remove the rear suspension upper front arm and bushing retainer bolt. - Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5519 17. Remove the rear suspension arm retainer bolt, and position the rear suspension arm and bushing out of the way. - Repeat for the other side. 18. Remove the lower shock absorber retainer bolt. - Repeat for the other side. 19. Remove the rear axle housing vent hose. 20. CAUTION: Watch for obstructions. Lower the rear axle on the jack until it is clear of the vehicle. INSTALLATION 1. WARNING: USE EXTRA STRAPS TO SECURE THE REAR AXLE TO THE JACK. Raise the rear axle into place using a suitable hydraulic jack. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5520 2. Position the rear suspension upper front arm and bushing, and install the retainer bolt. - Repeat for the other side. 3. Position the rear suspension arm and bushing and install the retainer bolt. - Repeat for the other side. 4. Raise the rear axle with the jack until the rear suspension arm and bushing are parallel to the ground, and install the shock absorber retainer bolts. - Repeat for the other side. 5. Tighten the rear suspension arm and bushing. - Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5521 6. Tighten the rear suspension upper front arm and bushing retainer bolt. - Repeat for the other side. 7. Position the rear axle tracking bar in the bracket, install the retainer bolt and tighten it. 8. Connect the rear axle housing vent hose. 9. Install and tighten the rear stabilizer bar retainer bolts. - Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5522 10. Tighten the rear stabilizer bar links and bushings. 11. Tighten the shock absorber retainer bolts. - Repeat for the other side. 12. Remove the jack. 13. Install the driveshaft, and tighten the retainer capscrews. 14. Partially lower the vehicle. 15. Install the jounce bumper retainer bolts and tighten. - Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5523 16. Connect the parking brake rear cable and conduit. - Repeat for the other side. 17. Install the rear disc brake rotor. - Repeat for the other side. 18. Install a new O-ring. - Repeat for the other side. 19. Install the rear disc brake caliper. - Repeat for the other side. 20. Install the wheels and tires. 1 Position the tire and wheel assembly. 2 Install the lug nuts, and lower the vehicle. 3 Tighten the lug nuts. 4 Install the center cap. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5524 21. Connect the air suspension height sensor. 22. Connect the electrical connector. 23. Lower the vehicle. 24. Turn on the air suspension control switch. Coil Suspension REMOVAL 1. Raise and support the vehicle. 2. Remove the rear wheel and tire assembly. 3. Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. 4. Remove the four driveshaft bolts, and disconnect the driveshaft. - Wire the driveshaft aside. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5525 5. Disconnect the electrical connector. 6. Disconnect the parking brake rear cable and conduit from the rear wheel disc brake adapter. - Repeat for the other side. 7. Remove the rear disc brake caliper, and position it out of the way. - Repeat for the other side. 8. CAUTION: Whenever the O-ring is removed, install a new one. Remove the O-ring. Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5526 9. Remove the rear disc brake rotor. - Repeat for the other side. 10. Remove the rear stabilizer bar retainer bolts. - Repeat for the other side. 11. Loosen the rear stabilizer bar links and bushings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5527 12. Install jack stands beneath the rear axle and lower the vehicle onto the jack stands. - Place a third jack stand under the front of the rear axle housing. 13. Remove the rear axle tracking bar assembly retainer bolt, and position the rear axle tracking bar out of the way. 14. Remove the jounce bumper. - Repeat for the other side. 15. Remove the rear suspension upper front arm and bushing retainer bolt. - Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5528 16. Remove the rear suspension arm and bushing retainer bolt, and position the rear suspension arm and bushing out of the way. - Repeat for the other side. 17. Remove the lower shock absorber retainer bolt. - Repeat for the other side. 18. Remove the rear axle housing vent hose. 19. CAUTION: This step requires an assistant to keep the axle clear of obstructions while the vehicle is being raised. Raise the vehicle clear of the rear axle. 20. Remove both rear springs. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5529 1. CAUTION: This step requires the aid of an assistant. Position the rear axle on jack stands under the vehicle. Place a third jack stand under the front of the carrier so that it points slightly upward. This will allow the control arms to clear the rear axle when the vehicle is lowered. 2. Lower the vehicle onto the rear axle. 3. Position the rear suspension upper front arm and bushing, and install the retainer bolt. - Repeat for the other side. 4. Position the rear suspension arm and bushing and install the retainer bolt. - Repeat for the other side. 5. Raise the vehicle, and position a suitable hydraulic jack under the rear axle housing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5530 6. Raise the rear axle with the jack until the rear suspension arm and bushings are parallel to the ground, and install the lower shock absorber retainer bolts. 7. Tighten the rear suspension arm and bushing. - Repeat for the other side. 8. Tighten the rear suspension upper front arm and bushing retainer bolt. - Repeat for the other side. 9. Lower the rear axle until it is hanging freely. 10. Install both rear springs. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5531 11. Raise the rear axle, position the rear axle tracking bar in the bracket, install the retainer bolt and tighten it. 12. Connect the rear axle housing vent hose. 13. Install and tighten the rear stabilizer bar retainer bolts on both sides. 14. Tighten the rear stabilizer bar links and bushings securely on both sides. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5532 15. Tighten the lower shock absorber retainer bolts on both sides. 16. Lower the jack, and remove it. 17. Install the driveshaft, and tighten the retainer capscrews. 18. Partially lower the vehicle. 19. Install the jounce bumper retainer bolts and tighten. - Repeat for the other side. 20. Connect the parking brake rear cable and conduit. - Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5533 21. Install the rear disc brake rotor. - Repeat for the other side. 22. Install a new O-ring. - Repeat for the other side. 23. Install the rear disc brake caliper. - Repeat for the other side. 24. Install the wheels and tires. 1 Position the tire and wheel assembly. 2 Install the lug nuts, and lower the vehicle. 3 Tighten the lug nuts. 4 Install the center cap. 25. Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5534 26. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5535 Differential Axle Housing: Service and Repair Front Drive Axle Removal and Installation REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. With the transmission in Neutral, raise and support the vehicle. 2. Index mark the front driveshaft to the front axle universal joint flange. 3. CAUTION: Do not allow the driveshaft to hang unsupported. Disconnect the front driveshaft. 1 Remove the four bolts. 2 Carefully disconnect and support the front driveshaft. 4. CAUTION: Do not allow the halfshaft to hang unsupported. Remove the six front drive halfshaft bolts and disconnect the front drive halfshaft. Repeat Step 4 for the opposite side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5536 5. Disconnect the vacuum lines and the front axle vent tube. 6. Use a high-lift jack to support the front drive axle/differential. 7. Remove the front differential support. 1 Remove the front carrier bushing nut and bolt. 2 Remove the front differential support nuts and bolts. 3 Remove the front differential support. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5537 8. Remove the right axle tube bushing nut and bolt. 9. Remove the differential cover bushing nut and bolt. 10. Carefully lower the front drive axle assembly. 11. Place the drive axle assembly in a suitable holding fixture. INSTALLATION 1. Use a high-lift jack to position the front drive axle assembly. 2. Install the differential cover bushing nut and bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5538 3. Install the right axle tube bushing bolt and nut. 4. Install the front differential support. 1 Position the front differential support. 2 Install the bolts and nuts. 3 Install the carrier bushing bolts and nuts. 5. Remove the high-lift jack. 6. Connect the vacuum lines and the front axle vent tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5539 7. Position the front drive halfshafts and install the six front drive halfshaft bolts on each side. 8. Align the index marks, then attach the front driveshaft. 9. Lower the vehicle. 10. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Disassembly Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5540 Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5541 Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5542 Special Tools 1. Remove the front drive axle assembly. 2. Remove the axle housing cover. 1 Remove the drain plug. 2 Drain the differential fluid. 3 Remove the bolts. 4 Remove the differential cover. 3. CAUTION: Fixture mounting bolts must have a minimum thread depth in the carrier. Install the front drive axle assembly in the Bench Mounted Holding Fixture. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5543 4. Unseat the clutch shaft rod boot, and remove the snap ring. 5. Disconnect the front axle actuator motor assembly. 1 Fully extend the front axle actuator motor shaft. 2 Plug the vacuum ports. 3 Pull the front axle actuator motor assembly out. 4 Push the front axle actuator motor assembly away, disconnecting the lever from the slot in the actuator motor shaft. 6. Remove the front axle actuator motor assembly and boot. 1 Remove the boot. 2 Remove the front axle actuator motor assembly. 7. Remove the front axle housing tube assembly. - Reposition the front drive axle assembly in the Bench Mounted Holding Fixture. - Remove the bolts. - Remove the front axle housing tube assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5544 8. Remove the cluster gear clutch thrust washer. 9. Remove the front axle cluster gear. 10. Remove the front axle shaft pilot bearing from the front axle cluster gear. 1 Position the front axle cluster gear in the vise. 2 Use Blind Hole Puller and Slide Hammer to remove the front axle shaft pilot bearing. 11. Lift the front axle shift lever and remove the selector gear. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5545 12. NOTE: Clearance is provided in casting for roll pin removal. If necessary, remove the shift lever assembly and the shift fork assembly. Drive the manual shaft retaining pin through the shift fork. - Remove the shift lever assembly and the shift fork assembly. 13. Remove the axle shaft. 1 Reposition the carrier assembly in the Bench Mounted Holding Fixture. 2 Remove the axle shaft snap ring. 3 Remove the axle shaft 14. CAUTION: Housing spreader adapter bolts have a minimum thread engagement. Install the left and right Housing Spreader Adapter tools. 15. Position the Carrier Housing Spreader on the spreader adapters. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5546 16. If necessary, adjust the Carrier Housing Spreader to provide clearance for the shift lever. 17. Install the Dial Indicator and Bracketry and position with the tip in the spreader adapter hole. 18. Spread the front axle housing. 1 Adjust the Dial Indicator to zero. 2 Tighten the housing spreader screw until the front axle housing is spread to specification. 3 Remove the Dial Indicator. 19. NOTE: Differential bearing caps must be installed in the original place and position. See reference arrows on differential bearing caps. Remove the differential bearing caps. 1 Remove the bolts. 2 Remove the differential bearing caps and mark or tag them right or left. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5547 20. CAUTION: Wood blocks must be used to avoid front axle housing damage. Remove the differential case from the front axle housing. 1 Position the wood blocks. 2 Use two pry bars and push down on the pry bars. 3 Remove the differential case. 4 Remove Differential Housing Spreader. 21. Mark the front axle universal joint flange and index it to the pinion stem. 1 Reposition the front axle housing in the Bench Mounted Holding Fixture. 2 Mark the front axle universal joint flange and index it to the pinion stem. 22. Install the Companion Flange Holding Tool with bolts, and loosen the pinion nut. 23. With the pinion nut still engaged by a few threads, install the 2-Jaw Puller and remove the front axle universal joint flange. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5548 24. Remove the pinion from the carrier housing. 1 Hold the pinion inside the carrier housing. 2 Use a soft face hammer and remove the pinion from the carrier housing. 25. CAUTION: Do not damage the front axle housing while removing the pinion seal. Remove the pinion seal and oil slinger. 26. Use the Puller Tool and the Slide Hammer to remove the inner bearing cup. 27. NOTE: A baffle to aid bearing lubrication is positioned behind the inner bearing cup. Normally this can be left in position if the inner bearing cup is removed. If necessary, remove the baffle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5549 28. Remove the outer axle pinion bearing cup, tapping alternately on each side to prevent the outer axle pinion bearing cup from cocking. 29. Remove the differential pinion bearing. - Install the Pinion Bearing Cone Remover on the differential pinion bearing assembly. - Position the Pinion Bearing Cone Remover and the differential pinion bearing assembly in a press and press the bearing off. 30. NOTE: Measure the drive pinion bearing adjustment shim (which is found under the differential pinion bearing) with a micrometer and record the thickness (use this as a reference to compare the shim gauge reading prior to installing the differential pinion bearing). Remove the drive pinion bearing adjustment shim from the differential pinion gear. 31. Remove the differential ring gear. - Remove the ten differential ring gear bolts. - Use a drift punch to separate the differential ring gear from the differential case. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5550 32. Use the 2-Jaw Puller and the Step Plate to remove the differential bearings. Assembly 1. CAUTION: Do not omit the baffle; bearing failure can result. If the baffle was removed, position the baffle on the Differential Bearing Cone Replacer. 2. Use the Differential Bearing Cone Replacer to install the baffle. 3. NOTE: Whenever the front pinion bearing cups are replaced, the differential pinion bearing must be replaced. Oil the new pinion bearing cups with Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL meeting Ford specification WSP-M2C201-A or equivalent and install. Use the Pinion Bearing Cup Replacer to install the bearing cups. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5551 4. NOTE: Apply only a light oil film on the pinion bearings before performing this measurement. Assemble and position the Pinion Depth Gauge Set. 1 Position the Screw. 2 Position the Aligning Adapter. 3 Position the Gauge Disc. 4 Position the Gauge Block. 5 Position the differential pinion bearing. 6 Position the differential pinion bearing. 7 Thread on the Driver Handle. 5. Tighten the Driver Handle to simulate bearing preload. 6. NOTE: The gauge block must be offset to obtain an accurate reading. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5552 Rotate the gauge block several half turns to ensure proper seating of the pinion bearings, and position the gauge block. 7. Install the Gauge Tube. 1 Position the gauge tube and paper shipping tags. 2 Install the differential bearing caps. 3 Install the bolts. 8. NOTE: Drive pinion bearing adjustment shims must be flat and clean. NOTE: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the gauge block and the gauge tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in final assembly of integrated rear axle assemblies. Use a drive pinion bearing adjustment shim as a gauge for shim selection. The pinion bearing adjustment shim is checked between the gauge block and the gauge tube. 9. NOTE: The same pinion bearing used in this procedure must be used in final axle assembly. Install the pinion bearing. Place the drive pinion bearing adjustment shim on the pinion. - Using a press and the Pinion Bearing Cone Replacer, press the differential pinion bearing until it is firmly seated on the pinion. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5553 10. If removed, place a new differential drive pinion collapsible spacer on the pinion stem. 11. Install the differential pinion bearing and differential pinion seal. 1 Position the differential pinion bearing. 2 Position the front axle drive pinion shaft oil slinger. 3 Position the differential pinion seal. 4 Use Pinion Seal Replacer to install the differential pinion seal. 12. Position the pinion gear. 1 Apply a small amount of Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A to the pinion gear splines. 2 Position the pinion gear. 13. CAUTION: The universal joint flange must never be hammered on or installed with power tools. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5554 Align the index marks and position the universal joint flange onto the pinion shaft. 14. NOTE: Rotate the pinion occasionally to ensure proper differential pinion bearing seating. Using the Companion Flange Replacer, install the front axle universal joint flange. 15. Apply a small amount of lubricant to the washer side of the new pinion nut, and install the nut. 16. NOTE: Never back off the pinion nut to reduce preload. If reduced preload is required, a new differential drive pinion collapsible spacer and pinion nut must be installed. Take frequent differential pinion bearing torque preload readings until the specified preload reading is obtained. Refer to the specification chart. Tighten the pinion nut. Position the Companion Flange Holding Tool and install the two companion flange holding tool bolts. - Tighten the pinion nut. CAUTION: Use extreme care not to damage the aluminum front axle housing while performing these procedures. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5555 17. CAUTION: Dummy bearings are marked LH and RH and must be installed as shown. Install the Dummy Bearing (LH) and Dummy Bearing (RH) on the differential case. 18. Install the differential case with master bearings into the front axle housing. 19. NOTE: Repeat this step until a consistent reading is obtained. Measure the total end play. 1 Position the Dial Indicator and Bracketry. 2 Position the indicator tip on the machined surface and adjust to measure full travel. 3 Push the differential case left and right (as far as possible). 4 Measure the total end play and record the reading on the Differential Bearing Shim Selection Procedure Worksheet Line A. 20. Remove the differential case. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5556 1 Remove the Dial Indicator Bracketry and Dial Indicator. 2 Remove the differential case. 21. Use a fine flat file to remove any burrs or nicks from the differential ring gear and pinion mounting surface. 22. Install the ring gear. - Position and then start three ring gear bolts to align the holes in the ring gear and the differential case. - Use an appropriate press to install the ring gear. 23. Install the remaining ring gear bolts. 24. Remove the three ring gear bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5557 25. Position the differential case. 1 Install the Dummy Bearing (LH) and the Dummy Bearing (RH) on the differential case. 2 Position the differential case in the front axle housing with the three missing bolts positioned down. 26. Position the Dial Indicator and Bracketry. 27. Push and rock the ring gear into mesh with the pinion gear (zero backlash) and set the Dial Indicator at zero. 28. Move the ring gear away from the pinion gear as far as possible and record the reading on the drive Pinion Bearing Adjustment Shim Selection Procedure Worksheet Line B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5558 29. Remove the Dial Indicator and Bracketry. 30. Remove the differential case, the Dummy Bearing (LH) and the Dummy Bearing (RH). 31. NOTE: Both differential bearing stand heights must be measured prior to installation on the differential case. NOTE: Mark the left and right differential bearings before measuring. Clamp the Bearing Preload Tool base in a soft jawed vise with the bearing mounting surface above the surface of the vise. 32. Position the differential bearing assembly in the Bearing Preload Tool and tighten the tool. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5559 33. Measure the differential bearing stand height. 1 Invert the Bearing Preload Tool and bearing assembly in the vise. 2 Use a depth micrometer to measure and record the differential bearing stand height. - Repeat the procedure for the other bearing. 34. Select appropriate differential bearings. Pinion Bearing Adjustment Shim Selection Procedure Worksheet Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5560 35. Select the appropriate shim by the thickness or the stripe color. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5561 Differential Shim Size Chart 36. Install the three ring gear bolts. 37. Install the differential bearings. 1 Position the appropriate differential bearing (RH or LH). 2 Use the appropriate press to install the differential bearing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5562 - Repeat for the other differential bearing. 38. NOTE: Make sure the indicator needle is in the spreader adapter hole. Install the Dial Indicator Bracketry and Dial Indicator. 1 Install the Differential Housing Spreader. 2 Install the Dial Indicator Bracketry, the Dial Indicator and the Clutch Housing Alignment Adapter. 39. CAUTION: Overspreading can cause damage to the front axle housing. Spread the front axle housing. 40. CAUTION: Never attempt to drive differential bearing shim in place. The front axle housing machined surfaces can be permanently damaged. If removed, position the differential bearing shims. 1 Apply a light coating of Premium Long Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B to one side of the differential bearing shims to help hold them in place. 2 Position the differential bearing shims. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5563 41. NOTE: Push the differential case down to fully seat the differential bearing cups in the front axle housing. Position the differential case assembly. 1 Position the differential bearing cups on the differential bearings. 2 Lower the differential case assembly in place between the differential bearing shims. 42. Install the bearing caps in their original positions and tighten with the housing still spread. 1 Position the bearing caps. 2 Install the bolts. 43. Remove the Differential Housing Spreader and reposition the Dial Indicator Bracketry. 44. NOTE: Measure the ring gear backlash at four places to obtain consistent reading. Measure the ring gear backlash. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5564 1 Mount the dial indicator on the indicator base. 2 Position the indicator needle and zero the indicator. 3 Turn the ring gear without turning the pinion gear and record the measurement. Refer to the specification chart. NOTE: If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount. 45. To increase the backlash, install the thicker differential bearing shim and the thinner differential bearing shim as shown. 46. To decrease backlash, install the thicker differential bearing shim and the thinner differential bearing shim as shown. 47. Lubricate and install the shift lever O-ring. - Use Ford Silicone Brake Caliper Grease and Dielectric Compound D7AZ-l9A331-A or WA-10 or equivalent meeting Ford specification ESE-MlC171-A. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5565 48. Install the shift lever. 1 Position the shift fork. 2 Install the shift lever, aligning the manual shift retaining pin holes. 49. Install the manual shaft retaining pin flush with the shift lever. 50. Lift the shift lever and position the selector gear, tapered end down, into the shift fork. 51. Use the Driver Handle and the Inner Axle Shaft Bearing Replacer to install the front axle shaft pilot bearing into the cluster gear. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5566 52. Insert the cluster gear through the selector gear and engage the splines. 53. CAUTION: The differential cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to snake sure the silicone sealant has properly cured. Use Premium Long Life Grease XG-l-C or -K or equivalent meeting Ford specification ESA-M1C75-B to coat the thrust washer and position it on the cluster gear. 54. CAUTION: Do not allow any silicone rubber to squeeze inside during assembly. Use Ford Black Silicone Rubber F4AZ-l9562-B or equivalent meeting Ford specification WSE-M4G323-A1 and ESE-M46l95-A to fill the groove in the front axle assembly. 55. Assemble the front axle tube. - Align the bolt holes and position the front axle tube assembly. - Position the axle identification tag. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5567 - Install the bolts. 56. Examine the axle shaft seal and bearing surface for damage. If necessary, polish the bearing surface with fine crocus cloth. 57. Insert the axle shaft and engage it with the side gear. 58. NOTE: Do not reuse the old snap ring. Push in on the axle shaft and install a new snap ring. 59. Install the dust boot. 1 Fully extend the actuator motor shaft and plug the vacuum port. 2 Position the actuator motor. 3 Install the dust boot. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5568 60. With the actuator motor shaft fully extended and the vacuum port plugged, engage the shift lever. 61. Seat the actuator motor and install the snap ring. 62. Seat the dust boot in the slot in the actuator housing. NOTE: Replace the vacuum motor if any vacuum leakage is observed. NOTE: With the lever moved outboard, the axle is engaged and the axles will turn opposite of each other. With the lever moved inboard, the axle is disengaged and the axles will turn freely of each other. 63. Verify the vacuum motor operation (engage). - Use the Vacuum Pump to apply vacuum to the outer vacuum port to move the shift lever outboard. Rotate one axle shaft to verify engagement. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5569 64. Verify the vacuum motor operation (disengage). - Use the Vacuum Pump to apply vacuum to the inner vacuum port to move the shift lever inboard. Rotate one axle to verify disengagement. 65. Remove the axle assembly from the Bench Mounted Holding Fixture and place it on the bench. 66. CAUTION: The differential cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has properly cured. Use Ford Black Silicone Rubber F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-A1 and ESE-M46195-A to fill the sealing groove on the axle housing cover. 67. Install the axle housing cover. 1 Position the axle housing cover. 2 Install the bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5570 68. Fill the differential housing and install the oil filler plug. - Use Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL meeting Ford specification WSP-M2C201-A or equivalent. - Install the front drive axle assembly. Axle Tube Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5571 Special Tools DISASSEMBLY 1. Remove the front axle tube from the front drive axle assembly. 2. Position and secure the front axle tube assembly in a vise. 3. Remove the clutch gear. 1 Remove the gasket from the sealing groove and flange face. 2 Push the axle shaft in and remove the snap ring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5572 3 Remove the clutch gear. 4. Remove the steel thrust washer and the tanged thrust washer. 5. Remove the axle shaft assembly. 6. Use the Bearing Cup Puller and the Slide Hammer to remove the inner bearing. 7. Reposition the axle tube in the vise and remove the axle dust seal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5573 8. Use the Bearing Cup Puller and the Slide Hammer to remove the outer bearing. CAUTION: Do not damage seal or bearing surfaces. 9. If damaged, remove the dust shield from the axle shaft. ASSEMBLY 1. NOTE: Use the appropriate side of the Needle Bearing Replacer to install the inner bearing. Install the inner bearing. Position the axle tube in a vise. - Position the inner bearing. - Use the Needle Bearing Replacer and the Driver Handle to install the inner bearing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5574 NOTE: The bearing is installed correctly when the flange of the tool bottoms out on the tube flange. 2. Install the outer bearing. - Position the axle tube in the vise. - NOTE: Use the appropriate side of the Needle Bearing Replacer to install the outer bearing. Use the Driver Handle and the Needle Bearing Replacer to install the outer bearing. NOTE: Make sure the axle shaft seal flange is flush with the axle tube. 3. Use the Driver Handle and the Axle Shaft Seal Replacer to install the axle shaft seal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5575 4. If removed, position the axle shaft dust deflector. 1 Position the Axle Bearing/Seal Plate on the press bed. 2 Position the Outer Shaft Deflector Replacer. 3 Position the axle shaft dust deflector. 5. If removed, use the appropriate press to press the axle shaft dust deflector on the axle shaft. 6. Insert the axle shaft into the axle tube housing. 7. Install the tanged thrust washer and steel thrust washer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Drive Axle > Page 5576 8. Install the clutch gear. 1 Install the tanged washer. 2 Lubricate and install the steel thrust washer. Use Premium Long Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B to coat the steel thrust washer and position it on the clutch gear. 3 Install the clutch gear. 9. Push in on the axle shaft and install a new snap ring and flange gasket. 10. Install the front axle tube to the front drive axle assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Drain Plug, Differential > Component Information > Specifications Drain Plug: Specifications TORQUE SPECIFICATIONS Oil Filler Plug ....................................................................................................................................... ..................................... 20-40 Nm (15-30 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Differential Fluid Capacity Capacity (Refill) ................................................................................................................................... .................................................................... 3.7 Pints Rear Differential Fluid Capacity Capacity (Refill) ................................................................................................................................... .................................................................... 5.8 Pints Fill no higher than 1/4 to 9/16 inch below fill plug. Add 4 oz. of friction modifier C8AZ-19B956-A for Traction-Lok differentials or equivalent meeting Ford specification EST-M2C118-A for Traction-Lok Axles. To determine standard or limited slip type, check axle code on label on door lock pillar. Standard axles consist of two numbers. Limited slip codes consist of one letter and one number. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 5584 Fluid - Differential: Fluid Type Specifications Front Front Axle Fluid Ford Part Number ................................................................................................................................................. Motorcraft SAE 75W90 Axle Lubricant Rear Rear Axle Fluid Ford Part Number ....................................................................................................................... Motorcraft SAE 75W140 Synthetic Rear Axle Lubricant Note: Your vehicles rear axle is equipped with synthetic rear axle lubricant. Rear axles containing synthetic lubricant are lubricated for life. These lubricants are not to be checked or changed unless a leak is suspected, service required or the axle has been submerged in water. The axle lubricant should be changed any time the axle has been submerged in water. Add 118 ml (4 oz.) of additive friction modifier C8AZ-19B546-A, Ford specification EST-M2C118-A whenever the fluid is changed. Service refill capacities are determined by filling the rear axle 6 mm to 14 mm (1/4 inch to 9/16 inch) below the bottom of the filler hole. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Front Drive Axle Pinion Bearing: Specifications Front Drive Axle TORQUE SPECIFICATIONS Differential Side Bearing Cap Bolts ......................................................................................................................................... 95-115 Nm (70-85 ft. lbs.) Pinion Bearing Torque Preload Used Pinion Bearing ......................................................................................................................................................... 0.9-1.5 Nm (8-14 inch lbs.) New Pinion Bearing ........................................................................................................................................................ 1.8-3.3 Nm (16-29 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Front Drive Axle > Page 5589 Pinion Bearing: Specifications 8.8 Inch Ring Gear TORQUE SPECIFICATIONS Differential Bearing Cap Bolt .................................................................................................................................................. 95-115 Nm (70-85 ft. lbs.) Pinion Bearing Preload (Used Pinion Bearings) ..................................................................................................................... 0.9-1.5 Nm (8-14 inch lbs.) Pinion Bearing Preload (New Pinion Bearings) ................................................................................................................... 1.8-3.3 Nm (16-29 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Front Drive Axle > Page 5590 Pinion Bearing: Specifications 9.75 Inch Ring Gear TORQUE SPECIFICATIONS Differential Bearing Cap Bolt .................................................................................................................................................. 95-115 Nm (70-85 ft. lbs.) Pinion Bearing Preload (Used Pinion Bearing) ...................................................................................................................... 0.9-1.5 Nm (8-14 inch lbs.) Pinion Bearing Preload (New Pinion Bearing) ..................................................................................................................... 1.8-3.3 Nm (16-29 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Specifications Pinion Flange: Specifications GENERAL SPECIFICATIONS - 9.75 INCH RING GEAR Rear Axle Companion Flange Maximum Radial Runout in Assembly ............................................................................................... 0.305 (0.012 T.I.R) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Specifications > Page 5594 Pinion Flange: Testing and Inspection WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: Pinion bearing preload must be reset if the pinion nut has been loosened or removed for companion flange re-indexing or replacement. 1. Raise the vehicle on a twin-post hoist that supports the rear axle. 2. Remove the driveshaft. 3. Check the companion flange for damage. 4. Position Companion Flange Runout Gauge on the companion flange. 5. Position the Clamp Plate onto the Companion Flange Runout Gauge. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Specifications > Page 5595 6. Align the holes on the clamp plate with the holes in the companion flange and install the bolts. Snug the bolts evenly. 7. Position the Dial Indicator/Magnetic Base as shown. Turn the Companion Flange Runout Gauge, and locate and mark the high spot on the companion flange with yellow paint. If the flange runout exceeds 0.25 mm (0.010 inch), remove the companion flange, re-index the flange one-half turn on the pinion, and reinstall it. 8. Check the runout again. If necessary, rotate the flange until an acceptable runout is obtained. If the flange runout is still more than 0.25 mm (0.010 inch), replace the companion flange. 9. If excessive runout is still evident after replacement of the companion flange, replace the ring and pinion. Repeat the above checks until the runout is within specifications. 10. Install the driveshaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle Pinion Flange: Service and Repair Front Drive Axle Special Tools REMOVAL WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: This operation disturbs the differential pinion bearing preload. This preload must be carefully reset when assembling. 1. Raise and support the vehicle. 2. Remove the front differential support. 1 Remove the front carrier bushing nut and bolt. 2 Remove the front differential support nuts and bolts. 3 Remove the front differential support. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5598 3. Index mark the front driveshaft to the front axle universal joint flange. 4. CAUTION: Do not allow the driveshaft to hang unsupported. Disconnect the front driveshaft. 1 Remove the four bolts. 2 Carefully disconnect the front driveshaft. 5. Use a lb/in torque wrench to measure the torque required to maintain rotation of the pinion and record the measurement for reference during installation. 6. Mark the front axle universal joint flange and index it to the pinion stem. 7. Loosen the pinion nut. 1 Position the Companion Flange Holding Tool and install the two companion flange holding tool bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5599 2 Loosen the pinion nut. CAUTION: Before proceeding, place a drain pan under the front axle housing. 8. With the pinion nut still engaged by a few threads, install the 2-Jaw Puller and remove the front axle universal joint flange. 9. Inspect the front axle universal joint flange for burrs and replace as necessary. Make sure that the surfaces of the front axle universal joint flange have not been damaged during removal. The end of the front axle universal joint flange that contacts the bearing cone, the nut counterbore and the seal surface must be smooth and free of nicks. 10. Check the splines on the pinion stem to be sure they are free of burrs. If burrs are evident, remove them with a fine crocus cloth. Working in a rotating motion, wipe the pinion clean. INSTALLATION 1. Lubricate the flange yoke seal splines and the seal. - Use Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. 2. CAUTION: The universal joint flange must never be hammered on or installed with power tools. Align the index marks and position the front axle universal joint flange onto the pinion shaft. 3. NOTE: Rotate the pinion occasionally to ensure proper differential pinion bearing seating. Using the Companion Flange Replacer, install the front axle universal joint flange. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5600 4. NOTE: If the original recorded preload is less than specification, tighten to specification. If the preload is higher than the specification, tighten to original reading as recorded. Never back off the pinion nut to reduce preload. If reduced preload is required, a new differential drive pinion collapsible spacer and pinion nut must be installed. Take frequent differential pinion bearing torque preload readings until the original recorded or specified preload reading is obtained. Install the pinion nut. 1 Position the Companion Flange Holding Tool and install the two companion flange holding tool bolts. 2 Tighten the pinion nut. 5. Align the index marks then attach the front driveshaft. 6. Install the front differential support. 1 Position the differential support. 2 Install the bolts and nuts. 3 Install the carrier bushing nuts and bolts. 7. Inspect and fill the differential fluid. - Use Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. 8. Lower the vehicle. 9. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5601 Pinion Flange: Service and Repair 8.8 Inch Ring Gear Special Tools REMOVAL 1. NOTE: The rear wheels and brake rotors must be removed to prevent brake drag during drive pinion bearing preload adjustment. Remove the rear brake rotors. 2. Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. 3. Remove the four driveshaft bolts and disconnect the driveshaft. Wire the driveshaft out of the way. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5602 4. Install a torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. 5. CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation. Use Companion Flange Holding Tool to hold the rear axle companion flange while removing the pinion nut. 6. Mark the driveshaft rear axle companion flange in relation to the drive pinion stem to ensure proper alignment during installation. 7. Use a 2-jaw puller for differential case bearings to remove the rear axle companion flange. INSTALLATION 1. Lubricate the rear axle companion flange splines. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5603 2. NOTE: Disregard the scribe marks if a new rear axle companion flange is being installed. Align the rear axle companion flange with the drive pinion shaft. 3. With the drive pinion in place in the rear axle housing, install the rear axle companion flange using the Companion Flange Replacer. 4. Position the new pinion nut. 5. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed. Use a suitable companion flange holding tool to hold the rear axle companion flange while tightening the pinion nut. Tighten the pinion nut, rotating the pinion occasionally to make sure the cone and roller bearings are seating properly. Take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained by rotating the pinion with a Nm (inch-pound) torque wrench. - If the original recorded preload is lower than specifications, tighten to the appropriate specification for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded. Refer to Torque Specifications. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5604 6. Position the rear driveshaft and align the marks on the rear axle companion flange. 7. Install the four rear driveshaft to rear axle companion flange bolts. 8. Install the rear brake rotors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5605 Pinion Flange: Service and Repair 9.75 Inch Ring Gear Special Tools SPECIAL TOOL(S) REMOVAL 1. NOTE: The rear wheels and brake rotors must be removed to prevent brake drag during drive pinion bearing preload adjustment. Remove the rear brake rotors. 2. Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. 3. Remove the four driveshaft bolts, and disconnect the driveshaft. Wire the driveshaft out of the way. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5606 4. Install a torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. 5. CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation. Use a companion flange holding tool to hold the rear axle companion flange while removing the pinion nut. 6. Mark the driveshaft rear axle companion flange in relation to the drive pinion stem to ensure proper alignment during installation. 7. Use the 2-Jaw Puller for Differential Case Bearings to remove the rear axle companion flange. INSTALLATION 1. Lubricate the rear axle companion flange splines. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5607 2. NOTE: Disregard the scribe marks if a new rear axle companion flange is being installed. Align the rear axle companion flange with the drive pinion shaft. 3. With the drive pinion in place in the axle housing, install the rear axle companion flange using the Companion Flange Replacer. 4. Position the new pinion nut. 5. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed. Use a suitable companion flange holding tool to hold the rear axle companion flange while tightening the pinion nut. - Tighten the pinion nut, rotating the pinion occasionally to make sure the cone and roller bearings are seating properly. Take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained by rotating the pinion with a Nm (inch-pound) torque wrench. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5608 - If the original recorded preload is lower than specifications, tighten to the appropriate specification for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded. Refer to Torque Specifications. 6. Position the rear driveshafts, and align the marks on the rear axle companion flange. 7. Install the four rear driveshaft-to-rear axle companion flange bolts. 8. Install the brake rotors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > Customer Interest for Pinion Gear: > 99-14-3 > Jul > 99 > Front Differential Moaning Noise In 2WD Mode Pinion Gear: Customer Interest Front Differential - Moaning Noise In 2WD Mode Article No. 99-14-3 07/12/99 ^ NOISE - "MOANING" FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE - VEHICLES BUILT THROUGH 4/15/1999 ^ AXLE - "MOANING" NOISE FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE VEHICLES BUILT THROUGH 4/15/1999 FORD: 1997-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-1999 NAVIGATOR ISSUE Some 4X4 vehicles built with center disconnect front axles may exhibit a "moaning" noise from the front differential while operating in 4X2 mode. The noise goes away when operating in 4X4 mode. This may be caused by the front differential side gears. ACTION Replace the front differential side gears with revised gears and replace the front differential pinion gears with revised gears. Refer to the following text for details. For vehicles that exhibit a front differential moan in 4X2 mode that goes away in 4X4 mode, replace both front axle side gears and both front axle pinion gears. Replace any worn or damaged pinion thrust washers and side gear washers. Refer to Section 205-03 of the appropriate model/year Workshop Manual for removal and installation procedures. PART NUMBER PART NAME XL3Z-4236-M Side Gears (2 Per Box) XL3Z-4215-M Pinion Gears (2 Per Box) DOAZ-4230-B Pinion Thrust washer C90Z-4228-B Side Gear washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991403A Replace Axle Side Gears 1.4 Hrs. And Pinion Gears DEALER CODING CONDITION BASIC PART NO. CODE 4235 42 OASIS CODES: 509000, 597997, 702100 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pinion Gear: > 99-14-3 > Jul > 99 > Front Differential - Moaning Noise In 2WD Mode Pinion Gear: All Technical Service Bulletins Front Differential - Moaning Noise In 2WD Mode Article No. 99-14-3 07/12/99 ^ NOISE - "MOANING" FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE - VEHICLES BUILT THROUGH 4/15/1999 ^ AXLE - "MOANING" NOISE FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE VEHICLES BUILT THROUGH 4/15/1999 FORD: 1997-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-1999 NAVIGATOR ISSUE Some 4X4 vehicles built with center disconnect front axles may exhibit a "moaning" noise from the front differential while operating in 4X2 mode. The noise goes away when operating in 4X4 mode. This may be caused by the front differential side gears. ACTION Replace the front differential side gears with revised gears and replace the front differential pinion gears with revised gears. Refer to the following text for details. For vehicles that exhibit a front differential moan in 4X2 mode that goes away in 4X4 mode, replace both front axle side gears and both front axle pinion gears. Replace any worn or damaged pinion thrust washers and side gear washers. Refer to Section 205-03 of the appropriate model/year Workshop Manual for removal and installation procedures. PART NUMBER PART NAME XL3Z-4236-M Side Gears (2 Per Box) XL3Z-4215-M Pinion Gears (2 Per Box) DOAZ-4230-B Pinion Thrust washer C90Z-4228-B Side Gear washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991403A Replace Axle Side Gears 1.4 Hrs. And Pinion Gears DEALER CODING CONDITION BASIC PART NO. CODE 4235 42 OASIS CODES: 509000, 597997, 702100 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Front Drive Axle Pinion Gear: Specifications Front Drive Axle TORQUE SPECIFICATIONS Differential Pinion Shaft Lock Bolt ........................................................................................................................................... 20-41 Nm (15-30 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Front Drive Axle > Page 5624 Pinion Gear: Specifications 8.8 Inch Ring Gear TORQUE SPECIFICATIONS Differential Pinion Shaft Lock Bolt ........................................................................................................................................... 20-40 Nm (15-30 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Front Drive Axle > Page 5625 Pinion Gear: Specifications 9.75 Inch Ring Gear TORQUE SPECIFICATIONS Differential Pinion Shaft Lock Bolt ........................................................................................................................................... 20-40 Nm (15-30 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear Pinion Gear: Service and Repair 8.8 Inch Ring Gear Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5628 Special Tools REMOVAL 1. Remove the differential case. 2. Mark the driveshaft flange and the driveshaft rear axle companion flange for correct alignment during installation. 3. Remove the four rear driveshaft bolts and disconnect the rear driveshaft. - Wire the driveshaft out of the way. 4. Install a Nm (inch-pound) torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. 5. Remove the rear axle companion flange and pinion nut. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5629 6. Using a soft-faced hammer, drive the pinion assembly out of the front bearing cone and remove it through the rear of the housing. 7. Use the bearing pulling attachment to remove the pinion bearing cone and roller assembly. 8. NOTE: Do not remove the pinion bearing cups from the carrier casting unless the cups are damaged. If the pinion bearing cups are to be replaced, tap alternately (with a brass drift of suitable length) on opposite sides of the cup during removal to prevent the cup from cocking in the casting. INSTALLATION 1. Drive the outer pinion bearing cup into the axle housing using the Pinion Bearing Cup Replacer and Driver Handle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5630 2. Drive the inner pinion bearing cup into the axle housing using the Pinion Bearing Cup Replacer and Driver Handle. 3. CAUTION: Whenever the cups are replaced, the pinion bearings must also be replaced. Make sure the cups are properly seated in their bores. If a feeler gauge can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not properly seated. 4. NOTE: Apply only a light oil film on the pinion bearings before assembling the tool. Assemble and position the Pinion Depth Gauge Set. 1 Position the Screw. 2 Position the Aligning Adapter. 3 Position the Gauge Disc. 4 Position the Gauge Block. 5 Position the inner pinion bearing. 6 Position the outer pinion bearing. 7 Thread on the Driver Handle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5631 5. Tighten the Driver Handle to the specification. 6. NOTE: The Gauge Block must be offset to obtain an accurate reading. Rotate the Gauge Block several half-turns to ensure proper seating of the pinion bearings and position the gauge block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5632 7. Install the Gauge Tube. 1 Position the Gauge Tube. 2 Install the differential side bearing caps. 3 Install the four differential side bearing cap bolts. 8. NOTE: Drive pinion bearing adjustment shims must be flat and clean. NOTE: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the Gauge Block and the gauge tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in final assembly of integral rear axle assemblies. Use a drive pinion bearing adjustment shim as a gauge for shim selection. 9. Use a press and Pinion Bearing Cone Replacer to press the pinion bearing until it is firmly seated on the pinion and pinion shim. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5633 10. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder. 11. From inside the rear axle housing, install the drive pinion assembly (drive pinion, shims, rear bearing cone and roller, and differential drive pinion collapsible spacer) into the rear axle carrier bore. 12. CAUTION: Installation without the proper tool can result in early seal failure. If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one. Install a new rear axle drive pinion seal. 1 Install the front pinion bearing cone and roller. 2 Install the rear axle drive pinion shaft oil slinger in the rear axle housing. 3 Install the rear axle drive pinion seal on the Pinion Seal Replacer. 13. NOTE: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Place the Pinion Seal Replacer in the rear axle drive pinion seal bore, and drive the rear axle drive pinion seal into place. 14. Lubricate the rear axle companion flange splines. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5634 15. NOTE: Disregard the scribe marks if a new rear axle companion flange is being installed. Align the rear axle companion flange with the drive pinion shaft. 16. With the drive pinion in place in the rear axle housing, install the rear axle companion flange using the Companion Flange Replacer. 17. Position the new pinion nut. 18. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed. Use a suitable companion flange holding tool to hold the rear axle companion flange while tightening the pinion nut. Refer to the torque specification for new pinion bearings. 19. Install the differential case in the rear axle differential carrier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5635 Pinion Gear: Service and Repair 9.75 Inch Ring Gear Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5636 Special Tools REMOVAL 1. Remove the differential case. 2. Mark the driveshaft flange and the driveshaft rear axle companion flange for correct alignment during installation. 3. Remove the four rear driveshaft bolts, and disconnect the rear driveshaft. - Wire the driveshaft out of the way. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5637 4. Remove the pinion nut. - Use a suitable companion flange holding tool. 5. Remove the rear axle companion flange using the 2-Jaw Puller for Differential Case Bearings. 6. Install Pinion Shaft Thread Protector and, with a soft-faced hammer, drive the pinion out of the front bearing cone and remove it through the rear of the housing. 7. Use the Bearing Pulling Attachment to remove the pinion bearing cone and roller assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5638 8. NOTE: Do not remove the pinion bearing cups from the carrier casting unless the cups are damaged. If the pinion bearing cups are to be replaced, tap alternately (with a brass drift of suitable length) on the opposite side of the cups during removal to prevent cups from cocking in the casting. INSTALLATION 1. Drive the outer pinion bearing cup into the axle housing, using the Pinion Bearing Cup Replacer (Outer) and the Driver Handle. 2. Drive the inner pinion bearing cup into the axle housing, using the Pinion Bearing Cup Replacer (Inner) and the Driver Handle. 3. CAUTION: Whenever the cups are replaced, the differential pinion bearings must also tee replaced. Make sure the cups are properly seated in their bores. If a feeler gauge of the specification shown in the illustration can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not properly seated. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5639 4. NOTE: Apply only a light oil film on the pinion bearings before assembling the tool. Assemble and position the Pinion Depth Gauge set. 1 Position the Screw. 2 Position the Pinion Depth Aligning Adapter. 3 Position the Gauge Disc. 4 Position the Gauge Block. 5 Position the inner pinion bearing. 6 Position the outer pinion bearing. 7 Thread on the Driver Handle. 5. Tighten the Driver Handle to the specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5640 6. NOTE: The Gauge Block must be offset to obtain an accurate reading. Rotate the Gauge Block several half-turns to ensure proper seating of the pinion bearings, and position the Gauge Block. 7. Install the Gauge Tube. 1 Position the Gauge Tube. 2 Install the differential side bearing caps. 3 Install the differential side bearing cap bolts. 8. NOTE: Drive pinion bearing adjustment shims must be flat and clean. NOTE: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in the final assembly of integral rear axle assemblies. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5641 9. Use a press and the Pinion Bearing Cone Replacer to press the pinion bearing until it is firmly seated on the pinion and pinion shim. 10. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder. 11. Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing. Seat the drive pinion with a plastic hammer. 12. CAUTION: Installation without the proper tool can result in early seal failure. If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one. Install a new rear axle drive pinion seal. 1 Install the outer pinion bearing cone and roller. 2 Install the rear axle drive pinion shaft oil slinger in the rear axle housing. 3 Install the rear axle drive pinion seal on the Pinion Seal Replacer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5642 13. NOTE: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Use a hammer to install the bearing, rear axle drive pinion seal and rear axle drive pinion shaft oil slinger. 14. Lubricate the rear axle companion flange splines. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 15. NOTE: Disregard the scribe marks if a new rear axle companion flange is being installed. Align the rear axle companion flange with the drive pinion shaft. 16. With the drive pinion in place in the axle housing, install the rear axle companion flange using the Companion Flange Replacer. 17. Position the new pinion nut. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5643 18. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed. Use a suitable companion flange holding tool to hold the rear axle companion flange while tightening the pinion nut. Refer to the torque specification for new pinion bearings. 19. Install the differential case. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Front Drive Axle Ring Gear: Specifications Front Drive Axle GENERAL SPECIFICATIONS Ring Gear Backlash ................................................................................................................................................... 0.203-0.330 mm (0.008-0.013 inch) Ring Gear Maximum Runout ...................................................... ............................................................................................................ 0.102-0.004 mm Ring Gear Bolts ..................................................................................................................................................... ................... 95-115 Nm (70-84 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Front Drive Axle > Page 5648 Ring Gear: Specifications 8.8 Inch Ring Gear TORQUE SPECIFICATIONS Ring Gear Bolts ................................................................................................................................... ..................................... 95-115 Nm (70-85 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Front Drive Axle > Page 5649 Ring Gear: Specifications 9.75 Inch Ring Gear GENERAL SPECIFICATIONS Maximum Back Face Ring Gear Runout ....................................................................................................................................... 1.102 mm (0.004 inch) Backlash Between Ring Gear and Pinion Teeth ............................................................................................................................................... 0.203-0.381 mm (0.305-0.381 preferred) ............................................................................................ ...........................................................................0.008-0.015 inch (0.012-0.015 preferred) Ring Gear Maximum Backlash Variation Between Teeth ..................................................................................................................... 0.102 mm (0.004) TORQUE SPECIFICATIONS Ring Gear Bolts ................................................................................................................................... ............................... 136-163 Nm (100-120 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional - 9.75 Inch Ring Gear Ring Gear: Service and Repair Conventional - 9.75 Inch Ring Gear Special Tools DISASSEMBLY 1. Remove the differential case. 2. Remove the ring gear bolts. 3. Insert a punch in the bolt holes and drive the ring gear off. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional - 9.75 Inch Ring Gear > Page 5652 4. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Remove the anti-lock speed sensor ring. 5. If required, remove the differential bearings with the 2-Jaw Puller for Differential Case Bearings and the Step Plate Adapter. 6. Remove the differential pinion shaft lock bolt and the differential pinion shaft. 7. Rotate and remove the differential pinion gears and differential pinion thrust washers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional - 9.75 Inch Ring Gear > Page 5653 8. Remove the differential side gears and the differential side gear thrust washers. ASSEMBLY 1. Position the differential side gear thrust washers on the differential side gears. - Use Motorcraft Synthetic Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A to lubricate the differential side gear thrust washers and the differential side gear journals. 2. Position the differential side gears. 3. Assemble the differential pinion thrust washers and the differential pinion gears. - Lubricate with Motorcraft Synthetic Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional - 9.75 Inch Ring Gear > Page 5654 4. Engage the differential pinion gears opposite the differential side gears. 5. Install the differential bearings, using the Differential Bearing Cone Replacer. 6. Rotate the differential pinion gears to align the differential pinion shaft bore. 7. Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight. 8. Press the new anti-lock speed sensor ring and the ring gear on the differential case. - The notch on the differential case flange and the notch on the anti-lock speed sensor ring must be aligned. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional - 9.75 Inch Ring Gear > Page 5655 9. Install the ring gear bolts and tighten. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. 10. Install the differential case. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional - 9.75 Inch Ring Gear > Page 5656 Ring Gear: Service and Repair Traction-Lok - 9.75 Inch Ring Gear Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional - 9.75 Inch Ring Gear > Page 5657 Special Tools DISASSEMBLY 1. Remove the differential case. 2. NOTE: The differential bearings need not be removed to overhaul the Ford limited slip differential. If bearing removal is required, use the 2-Jaw Puller for Differential Case Bearings and the Step Plate Adapter. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft. If required, remove the ring gear and anti-lock speed sensor ring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional - 9.75 Inch Ring Gear > Page 5658 3. Install the Traction-Lok(R) Torque Tool in a suitable vise. 4. Install the differential case on the tool. 5. Install the Step Plate Adapter in the bottom side gear bore. Apply a small amount of grease to the centering hole of the Step Plate Adapter. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional - 9.75 Inch Ring Gear > Page 5659 6. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw. Tighten the hex-head screw until contact is made with the Step Plate Adapter. 7. NOTE: The dowel bar is used to keep the nut from turning when the forcing screw is tightened. Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gear away from the differential pinion gears. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional - 9.75 Inch Ring Gear > Page 5660 8. WARNING: KEEP FINGERS/HANDS AWAY FROM PINION GEARS WHEN ROTATING THE DIFFERENTIAL CASE WITH THE DIFFERENTIAL ROTATING TOOL. NOTE: Differential pinion thrust washers cannot be removed independently of the differential pinion gears and so must be removed simultaneously with the differential pinion gears. Insert the Limited Slip Differential Rotating Tool in the pinion shaft bore, and turn the differential case to "walk" the differential pinion gears and differential pinion thrust washers out to the differential case windows. 9. Remove the differential pinion gears and differential pinion thrust washers. 10. Remove the differential side gears and differential clutch packs,and tag them RIGHT and LEFT with the shim. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional - 9.75 Inch Ring Gear > Page 5661 11. CAUTION: When separating the clutch plates and clutch discs, note the sequence in which they are disassembled. They must be reassembled in the same sequence. CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only. Separate the differential clutch discs and clutch plates for cleaning and inspection. Refer to the disassembled view of the limited slip differential case. ASSEMBLY 1. Prelubricate each steel clutch plate and soak all friction plates in Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes. 2. NOTE: Do not mix the differential clutch packs or shims from one side with the other. NOTE: The Belleville spring is a dished plate. Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional - 9.75 Inch Ring Gear > Page 5662 3. NOTE: Use the Traction-Lok(R) Clutch Gauge Mandrel for the procedure. Refer to the Special Tool(s) Chart. Clamp the bolt head of the Traction-Lok(R) Clutch Gauge in a vise. Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge. 4. Position the Traction-Lok(R) Clutch Gauge on top of the differential clutch pack. 5. Install the Traction-Lok Clutch Gauge over the disc and differential clutch pack. 6. Install the nut of the gauge over the top and base stud. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional - 9.75 Inch Ring Gear > Page 5663 7. Use the Feeler Gauge and select the thickest blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim. Select the correct shim size, and remove the Traction-Lok(R) Clutch Gauge. 8. Place the shim and Belleville spring on the differential clutch pack. - The dished or concave side of the Belleville spring must face up and against the thrust face of the differential case. ^ Refer to the Exploded View if necessary. See: Diagrams 9. Insert the differential clutch packs with shims and Belleville springs and differential side gears into the differential case. - Hold the upper clutch pack and side gear assembly in place to prevent it from falling out of the differential case. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional - 9.75 Inch Ring Gear > Page 5664 10. NOTE: Apply a small amount of grease to the step plate bore. NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened. Assemble the forcing screw, nut and step plate to the differential case. 1 Position the Step Plate Adapter in the bottom side gear bore. 2 Position the nut in the top side gear bore and hold it in place. 3 Install the hex-head screw and tighten it two turns after it contacts the bottom step plate. 11. NOTE: Prelubricate both sides of the differential pinion thrust washers with Motorcraft Synthetic Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. NOTE: Make sure the differential pinion gears are 180° apart so they will align correctly with the pinion shaft bore. Position the differential pinion gears and differential pinion thrust washers in the window of the differential case so they mesh with the differential side gear teeth. 12. WARNING: KEEP FINGERS/HANDS AWAY FROM PINION GEARS WHEN ROTATING THE DIFFERENTIAL CASE WITH THE DIFFERENTIAL ROTATING TOOL. NOTE: It will probably be necessary to loosen or tighten the forcing screw to allow the differential pinion gears and differential side gears to rotate. Insert the rotating handle into the pinion shaft bore, and turn the differential case. This will cause the differential pinion gears to engage the differential side gears and "walk" into the differential case. Rotate the differential case until the pinion mating shaft holes are lined up exactly with the holes in the differential pinion gears. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional - 9.75 Inch Ring Gear > Page 5665 13. Loosen the forcing screw, and remove the step plate and nut from the side gear bores. Install the differential pinion shaft in the differential case. - Install a new differential pinion shaft lock bolt finger-tight. 14. Replace the differential bearings, if removed, using the Differential Bearing Cone Replacer. 15. Using a press, install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the retaining bolts. - The notch on the differential case flange and the notch on the anti-lock speed sensor ring must be aligned. 16. Install the differential case. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle Seals and Gaskets: Service and Repair Front Drive Axle Special Tools REMOVAL 1. Remove the front axle universal joint flange. 2. CAUTION: Do not damage the front axle housing. Remove the pinion seal. INSTALLATION 1. Clean the pinion seal bore and use Pinion Seal Replacer to install the pinion seal. 2. Install the front axle universal joint flange. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 5670 Seals and Gaskets: Service and Repair 8.8 Inch Ring Gear Special Tools REMOVAL 1. Remove the rear axle companion flange. 2. Pry up on the metal flange of the pinion seal. Install gripping pliers and strike with a hammer until the pinion seal is removed. INSTALLATION 1. Lubricate the new rear axle drive pinion seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the rear axle drive pinion seal and replace with a new seal. Use Pinion Seal Replacer to install the rear axle drive pinion seal. 3. Install the rear axle companion flange. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 5671 Seals and Gaskets: Service and Repair 9.75 Inch Ring Gear Special Tools REMOVAL 1. Remove the rear axle companion flange. 2. Pry up on the metal flange of the pinion seal. Install gripping pliers and strike with a hammer until the pinion seal is removed. INSTALLATION 1. Lubricate the new pinion seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: If the pinion seal becomes misaligned during installation, remove the seal and replace with a new seal. Use the Pinion Seal Replacer to install the pinion seal. 3. Install the rear axle companion flange. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Mechanical Specifications Axle Shaft: Mechanical Specifications GENERAL SPECIFICATIONS Front Wheel Halfshaft and CV Joint Assembled Length ............................................................................................................................... .................................. 417.25 mm (16.43 inch) TORQUE SPECIFICATIONS Front Drive Halfshaft Bolts ........................................................................................................................................................ 68-92 Nm (51-67 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Mechanical Specifications > Page 5678 Axle Shaft: Capacity Specifications Lubricant Outboard .............................................................................................................................................. ............................... 165 Grams (5.82 Ounces) Inboard ...................................................................... .......................................................................................................... 235 Grams (8.29 Ounces) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 5679 Axle Shaft: Diagrams Disassembled View (Part 1 Of 2) Disassembled View (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 5680 Axle Shaft: Description and Operation Front Drive Halfshaft Disassembled View (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 5681 Disassembled View (Part 2 Of 2) The halfshaft assembly transmits equal engine torque from the axle to both front wheels. The halfshaft assembly uses a Constant Velocity (CV) joint, at both the inboard and outboard ends, for smooth operation. The CV joints rotate at approximately one-third the speed of a driveshaft and do not normally contribute to any rotational vibration that may occur. The only replaceable components of the halfshaft assembly are: Halfshaft joint boots (inboard and outboard). Replacement kit includes front wheel driveshaft joint boots and clamps, snap rings, retainer ring and grease. - Inboard CV joint (plunge type). - Side shaft. Replacement includes the outboard front wheel halfshaft joint (fixed type), outboard boot and clamps, front wheel excluder seal (assembled on the interconnecting shaft). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type Axle Shaft: Service and Repair Axle Shaft Assembly, Constant Velocity Type Removal and Installation Special Tools REMOVAL 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. Loosen the lug nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 1 Remove the lug nuts. 2 Remove the wheel and tire assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5684 4. Remove the hub nut. 1 Remove the cotter pin. 2 Remove the retainer. 3 Remove the hub nut. 5. Position the front disc brake caliper aside. 1 Remove the two caliper bolts. 2 Lift the front disc brake caliper off the front disc brake caliper anchor plate and position aside. 6. Remove the upper ball joint castle nut. 1 Remove the cotter pin. 2 Remove the castle nut. 7. Use Pitman Arm Puller to separate the front wheel knuckle from the front suspension upper arm. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5685 8. Remove the six front wheel halfshaft and joint bolts. 9. CAUTION: Use caution to avoid damaging the hub seal when removing the front drive halfshaft. Separate the halfshaft assembly from the hub and remove the halfshaft assembly from the vehicle. INSTALLATION 1. Install the six halfshaft bolts. 2. Install the caliper. 1 Position the caliper. 2 Install the caliper bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5686 3. Install the front axle hub. 1 Install the front axle hub nut. 2 Install the retainer. 3 Install the cotter pin. 4. Install the front suspension arm upper ball joint castle nut. 1 Position the front wheel knuckle. 2 Install the upper ball joint castle nut. 3 Install a new cotter pin. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 5. Install the tire and wheel assembly. 1 Position the tire and wheel assembly. 2 Install the lug nuts and lower the vehicle. 3 Tighten in the lug nuts in sequence. 4 Install the wheel cover. Disassembly and Assembly Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5687 Special Tools DISASSEMBLY 1. Remove the halfshaft and joint. 2. Slide the two inboard clamp protectors off the boot clamps. 3. CAUTION: Be careful not to damage the front wheel halfshaft joint boot. Remove the two inboard boot clamps. 4. Slide the inboard front wheel halfshaft joint boot off the inboard CV joint housing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5688 5. Remove the retaining ring. 6. Remove the inboard CV joint housing. 7. Mark the inner race and the ball cage for assembly. 8. Remove the six balls. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5689 9. Remove the snap ring. 10. Remove the inner race and ball cage. 11. Remove the inboard front wheel halfshaft joint boot and the clamp protector. 12. Remove the two outboard boot clamps. 1 Remove the outboard clamp protectors. 2 Grip the boot clamps and peel the clamps away from the boot. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5690 13. Remove the outboard front wheel halfshaft joint boot. 14. Inspect for contaminated grease. 15. If grease is contaminated, clean and inspect the joint for wear. Replace the outboard CV joint and interconnecting shaft assembly if worn or damaged. ASSEMBLY 1. Pack the outboard CV joint with grease. 1 Use High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A provided in the boot kit. 2 Spread any remaining grease from service kit evenly inside the outboard boot. 2. Position the outboard front wheel driveshaft joint boot and outboard boot clamps. 1 Clean the front wheel driveshaft joint boot mounting surface. 2 Position the outboard front wheel driveshaft joint boot in the outboard CV joint grooves and position boot clamps. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5691 3. NOTE: Tighten the through-bolt until installer is in the closed position. Use CV Boot Clamp Tool to install the boot clamps. 4. Install the two outboard clamp protectors. 5. Position the inboard clamp protector and the boot clamp on the halfshaft assembly. 6. Position the inboard front wheel halfshaft joint boot. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5692 7. Position the ball cage on the halfshaft assembly with the tapered end toward the front wheel driveshaft joint boot. 8. NOTE: Line up the marks made during disassembly. Position the inner race on the halfshaft assembly with the counterbored end towards the front wheel driveshaft joint boot. 9. Install the snap ring. 10. Lubricate and position the six balls. - Use High Temp Constant Velocity Joint Grease E43Z-19590-A provided in the boot kit meeting Ford specification ESP-MlC207-A. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5693 11. Position the clamp protector and the inboard boot clamp on the inboard CV joint housing. 12. Fill the inboard CV joint housing with 235 grams of grease. - Use High Temp Constant Velocity Joint Grease E43Z-19590-A provided in the boot kit meeting Ford specification ESP-M1C207-A. 13. Position the inboard CV joint housing and install the retaining ring. 14. Remove any excess grease from the mating surface and position the inboard front wheel halfshaft joint boot. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5694 15. Adjust the CV joint to boot spacing to specification. 16. NOTE: The air should be released only after adjusting the CV joint to boot spacing. Insert a dulled screwdriver blade to relieve built up air pressure in the front wheel halfshaft joint boot. 17. Use CV Boot Clamp Tool to install the two inboard boot clamps. 18. Position the clamp protectors over the inboard boot clamps. 19. Install the Halfshaft and joint. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5695 Axle Shaft: Service and Repair Axle Shaft, Conventional Fixed/Floating 8.8 Inch Ring Gear REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the axle housing cover. - Drain the lubricant. 4. Remove the rear brake rotors. 5. Remove the differential pinion shaft. 1 Remove the differential pinion shaft lock bolt. 2 Remove the differential pinion shaft. 6. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. Remove the U-washers. 1 Push the axle shafts inboard. 2 Remove the U-washers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5696 7. CAUTION: Do not damage the inner wheel bearing oil seal. Remove the two axle shafts. INSTALLATION 1. Lubricate the lip of the inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-MlC75-B. 2. CAUTION: Do not damage the inner wheel bearing oil seal. Install the two axle shafts. 3. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves. Install the U-washers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5697 1 Position the two U-washers on the button end of the axle shafts. 2 Pull the axle shafts outward. 4. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock(R) and Sealer EOAZ-1955l-AA or equivalent meeting Ford specifications WSK-M2G315-A5 and ESE-M4G204-A2 prior to installation. Install the differential pinion shaft. 1 Align the hole in the differential pinion shaft with the case lock bolt hole. 2 Install the lock bolt. 5. Install the rear brakes. 6. Install the rear axle housing cover and fill the rear axle housing with the correct amount of specified lubricant. 7. WARNING: ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL PRESENT ON THE MOUNTING SURFACES OF THE WHEEL OR THE SURFACE OF THE WHEEL HUB, BRAKE DRUM, OR BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUT TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. Clean the wheel hub and mounting surfaces. 8. Install the tire and wheel assembly. 1 Position the tire and wheel assembly. 2 Install the lug nuts and lower the vehicle. 3 Tighten the lug nuts. 4 Install the center cap. 9. Lower the vehicle. 9.75 Inch Ring Gear DISC BRAKE REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5698 2. Remove the wheel and tire assembly. 3. Remove the axle housing cover. - Drain the lubricant. 4. Remove the rear brake rotors. 5. Remove the differential pinion shaft. 1 Remove the differential pinion shaft lock bolt. 2 Remove the differential pinion shaft. 6. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves. Remove the U-washers. 1 Push the axle shafts inboard. 2 Remove the U-washers. 7. CAUTION: Do not damage the inner wheel bearing oil seal. Remove the two axle shafts. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5699 1. Lubricate the lip of the inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: Do not damage the inner wheel bearing oil seal. Install the two axle shafts. 3. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. Install the U-washers. 1 Position the two U-washers on the button ends of the axle shafts. 2 Pull the axle shafts outward. 4. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock(R) and Sealer EOAZ-19554-FF or equivalent meeting Ford specifications WSK-M2G315-A5 and ESE-M4G204-A2 prior to installation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5700 Install the differential pinion shaft. 1 Align the hole in the differential pinion shaft with the case lock bolt hole. 2 Install a new lock bolt. 5. Install the rear brake rotors. 6. Install the axle housing cover and fill the rear axle housing with the correct amount of specified lubricant. 7. WARNING: ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL ON THE MOUNTING SURFACES OF THE WHEEL OR THE SURFACE OF THE WHEEL HUB, BRAKE DRUM, OR BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUT TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. Clean the wheel hub and mounting surfaces. 8. Install the tire and wheel assembly. 1 Position the tire and wheel assembly. 2 Install the lug nuts and lower the vehicle. 3 Tighten the lug nuts. 4 Install the center cap. 9. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > 8.8 Inch Ring Gear Seals and Gaskets: Service and Repair 8.8 Inch Ring Gear Special Tools Special Tools REMOVAL 1. Remove the axle shaft. 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > 8.8 Inch Ring Gear > Page 5705 NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with debris. Use Impact Slide Hammer and Axle Wheel Bearing Puller to remove the rear wheel bearing and inner wheel bearing oil seal. INSTALLATION 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2Cl92-A. 2. Use Axle Wheel Bearing Replacer with Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-l-C or equivalent meeting Ford specification ESA-MlC75-B. 4. Use Axle Seal Replacer with Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > 8.8 Inch Ring Gear > Page 5706 Seals and Gaskets: Service and Repair 9.75 Inch Ring Gear DISC BRAKE Special Tools REMOVAL 1. Remove the axle shaft. 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with debris. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > 8.8 Inch Ring Gear > Page 5707 Use the Impact Slide Hammer and the Axle Bearing Remover to remove the rear wheel bearing and inner wheel bearing oil seal. INSTALLATION 1. Lubricate the new rear axle bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use the Axle Wheel Bearing Replacer with the Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Use the Axle Seal Replacer with the Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5712 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5713 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5714 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5715 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5716 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5717 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5718 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5719 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5720 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5721 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5722 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5723 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5724 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5725 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5726 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5727 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5728 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5729 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5730 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5731 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5732 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5733 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5734 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5735 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5736 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5737 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5738 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5739 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5740 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5741 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5742 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5743 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5744 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5745 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5746 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5747 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5748 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5749 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5750 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5751 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5752 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5753 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5754 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5755 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5756 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5757 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5758 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5759 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5760 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5761 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5762 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5763 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5764 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5765 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5766 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5767 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5768 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5769 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5770 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5771 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5772 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5773 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5774 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5775 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5776 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5777 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5778 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5779 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5780 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5781 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5782 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5783 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5784 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5785 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5786 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5787 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5788 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5789 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5790 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5791 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5792 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5793 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5794 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5795 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5796 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5797 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5798 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5799 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5800 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5801 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5802 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5803 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5804 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 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. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5805 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 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. 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 the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5806 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Page 5807 Wheel Bearing: Specifications Rear Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 REMOVAL NOTE: The wheel bearing and hub are replaced as an assembly. 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the wheel and tire assembly. 3. Remove the front disc brake rotor. 4. Remove the front wheel hub nut. (1) Remove the cotter pin. (2) Remove the retainer. (3) Remove the nut. 5. Remove the front disc brake rotor shield. (1) Remove the bolts. (2) Remove the front disc brake rotor shield. 6. Remove the front brake anti-lock sensor. (1) Remove the bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5810 (2) Remove the front brake anti-lock sensor. 7. Remove the wheel hub. (1) Remove the bolts. (2) Push the CV joint inboard. Remove the wheel hub. CAUTION: Do not over extend CV joint and boots when removing the hub and bearing assembly. NOTE: The CV joint is a slip fit into the wheel hub and bearing. A puller will not normally be required. 8. Remove the seal. INSTALLATION 1. Install the seal. - Use Knuckle Seal Replacer, Threaded Drawbar and Bearing Cup Replacer to install the seal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5811 2. Install the wheel hub. (1) Position the wheel hub on the front wheel driveshaft and joint and into the front wheel knuckle. (2) Install the bolts. 3. Install the front brake anti-lock sensor. (1) Install the front brake anti-lock sensor into the wheel hub. (2) Install the bolt. 4. Install the front disc brake rotor shield and front axle hub nut. (1) Position the front disc brake rotor shield. (2) Install the bolts. (3) Install the front axle hub nut. (4) Install the retainer. (5) Install cotter pin. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5812 5. Install the front disc brake rotor. 6. Install the tire and wheel assembly. (1) Position the tire and wheel assembly. (2) Install the lug nuts. (3) Tighten the lug nuts in the sequence indicated. (4) Install the center cap. WARNING: WHEN THE WHEEL IS INSTALLED, ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL THAT MAY BE PRESENT ON THE MOUNTING SURFACES OF THE WHEELS OR THE SURFACES OF THE WHEEL HUB, BRAKE DRUM OR BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUT TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. RETIGHTEN AT 800 KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. 7. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5813 Wheel Bearing: Service and Repair Rear 8.8 Inch Ring Gear Special Tools Special Tools REMOVAL 1. Remove the axle shaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5814 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with debris. Use Impact Slide Hammer and Axle Wheel Bearing Puller to remove the rear wheel bearing and inner wheel bearing oil seal. INSTALLATION 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2Cl92-A. 2. Use Axle Wheel Bearing Replacer with Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-l-C or equivalent meeting Ford specification ESA-MlC75-B. 4. Use Axle Seal Replacer with Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shafts. 9.75 Inch Ring Gear Models With Rear Disc Brakes Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5815 Special Tools REMOVAL 1. Remove the axle shaft. 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with debris. Use the Impact Slide Hammer and the Axle Bearing Remover to remove the rear wheel bearing and inner wheel bearing oil seal. INSTALLATION 1. Lubricate the new rear axle bearing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5816 - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use the Axle Wheel Bearing Replacer with the Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Use the Axle Seal Replacer with the Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Hub Nut 255-345 Nm (188-254 ft.lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 98-25-21 > Dec > 98 > Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Drive/Propeller Shaft: Customer Interest Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 98-18-7 > Sep > 98 > Steering/Driveline - High Speed Vibration Technical Service Bulletin # 98-18-7 Date: 980914 Steering/Driveline - High Speed Vibration Article No. 98-18-7 09/14/98 ^ STEERING COLUMN - HIGH SPEED VIBRATION - 4X4 VEHICLES EQUIPPED WITH COIL SUSPENSION ^ VIBRATION - HIGH SPEED VIBRATION - 4X4 VEHICLES EQUIPPED WITH COIL SUSPENSION LIGHT TRUCK: 1997-98 EXPEDITION 1998 NAVIGATOR This TSB article is being republished in its entirety to include the 1998 model year, revise the Service Procedure and include the latest level parts. ISSUE A vibration at highway speeds (approximately 97-113 km/h (60-70 mph)) may occur on some 4X4 vehicles with coil suspension. This vibration, present on cruise, however becomes more noticeable during coastdown. This may be caused by a driveline imbalance which produces a vibration in the seat, steering wheel, floorpan, and a rumble in the vehicle cabin. ACTION Refer to the following Service Procedure to determine the correct fix for the condition. PART NUMBER PART NAME F75Z-7H408-AA Transfer Case Output Plug XL1Z-4602-AA Driveshaft (5.4L Vehicles) XL1Z-4602-BA Driveshaft (4.6L vehicles) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-14-15 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:303000, 304000, 508000, 509000, 703000, 703300 Service Procedure 1. Drive the vehicle and verify the condition. Record all speeds, engine rpms and transmission gears that correspond to any boom, rumble or vibration that occurs. Note if the condition is cyclical, or if the condition severity changes by changing from 2H to AWD and 4H or by changing gears (3rd or OD), or the condition changes from cruise to coast and/or tip-in or tip-out. 2. Verify tire pressures are 207 kPa (30 psi) in the front tires and 241 kPa (35 psi) in the rear. If incorrect, correct tire pressure and redrive. If condition is not resolved, exchange all four tires with those of another Expedition or Navigator with same powertrain and wheel configuration which does not exhibit the condition. Redrive or properly calibrate wheel balancer and check the balance of the tires without removal of the factory weights. If tires are out of balance, rebalance and drive the vehicle. If the condition is not resolved, proceed to Step 3. 3. Both the driveshaft and the rear axle flange will have yellow paint dots. Verify that the driveshaft yellow dot and the rear axle flange yellow dot are aligned. If not aligned, rotate driveshaft at the rear axle flange so that the yellow dots are aligned and redrive. If the condition is still present, measure the driveshaft runout at both ends and in the middle. If the runout is over 0.030" at any location, replace the original double carden driveshaft with a new heavy duty single carden Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) and redrive. If the condition is still present, disconnect the driveshaft at the rear axle and measure the rear axle flange runout per the 1997 Expedition Workshop Manual, Page 205-00-25. If the flange runout is out of specification (spec is 0.011"), consult the Sterling Axle Plant Hotline at (800) FORD-AXL. Otherwise, proceed to Step 4. 4. Index the driveshaft in 90 degree increments around the rear axle flange and drive the vehicle after each reindexing. If condition is not resolved, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 98-18-7 > Sep > 98 > Steering/Driveline - High Speed Vibration > Page 5834 reindex the driveshaft so that the yellow dot is aligned with the yellow dot on the rear axle flange and proceed to Step 5. NOTE AFTER CONDUCTING STEPS 1-4 AND ENSURING THAT THE CONDITION IS NOT ORIGINATING FROM THE TIRES/WHEELS AND/OR DRIVESHAFT, IT IS POSSIBLE THAT THE CONDITION COULD BE ORIGINATING FROM THE TRANSFER CASE. A TRANSFER CASE CONDITION IS TYPICALLY CHARACTERIZED BY A NOTICEABLE INCREASE IN THE SEVERITY OF THE VIBRATION FROM AN ACCELERATION/COAST TO A DECELERATION DRIVE MODE. IF THE VIBRATION CONDITION BEING EXPERIENCED IS SIMILAR TO THIS VIBRATION, COMPLETE STEPS 5-7 TO IDENTIFY IF THE TRANSFER CASE IS CONTRIBUTING TO THE CONDITION. 5. Transfer case testing is as follows: a. Index the rear driveshaft in 45 degree increments at the transfer case only (maintain the same alignment with the rear axle flange) and redrive between each index. Note if the condition severity changes. This process may reach a point where the vibration is eliminated and/or reduced to an acceptable level. Does the condition disappear or change significantly? ^ If yes, return vehicle to customer. ^ If no, or customer returns unsatisfied, proceed to Step 5b. NOTE THE TRANSFER CASE REAR OUTPUT MUST BE PLUGGED SO THAT FLUID DOES NOT SPILL DURING VEHICLE OPERATION. USE PLUG F75Z-7H408-AA. b. Completely remove the rear driveshaft from the vehicle and redrive in 4H mode so that the vehicle is being driven through the front driveshaft only. Does the condition disappear or change significantly? ^ If yes, proceed to Step 6. ^ If no, proceed to Step 7. 6. If not already done in Step 3, replace the carden rear driveshaft with a heavy duty single carden driveshaft (refer to Step 3). When installing the new driveshaft, be sure to align both the driveshaft and rear axle flange yellow paint dots. Redrive vehicle in 2H at highway speeds to verify the condition has disappeared or improved significantly. If the double carden driveshaft was replaced in Step 3, or after completing Step 6, the redrive resulted in little or no improvement, proceed to Step 7. NOTE REAR DRIVESHAFT REMOVAL IS FOR TEMPORARY TEST USE ONLY AND IS NOT RECOMMENDED FOR LONG DURATIONS OF TRAVEL. WHILE DRIVING IN THIS CONDITION, NOISE AND VIBRATIONS WILL BE EXPERIENCED AT VARIOUS SPEEDS THAT MAY NOT HAVE BEEN NOTED PREVIOUSLY. THE PURPOSE OF THIS TEST IS TO DETERMINE IF THE ORIGINAL CONDITION HAS BEEN CHANGED. 7. If the vehicle was built on or before 7/15/97, call the Transfer Case Hotline at (765) 286-6234 to request a certified transfer case. Calls to the hotline will be screened to ensure that the diagnosis in this TSB article has been followed thoroughly and properly. If your vehicle is a good candidate for a transfer case exchange, a certified transfer case will be shipped to your dealership. Install the certified transfer case into the vehicle and redrive. If the condition is not resolved, or the vehicle was built after 7/15/97, proceed to Step 8. 8. Call the Sterling Axle Plant Hotline at (800) FORD-AXL for a certified rear axle. If new axle does not completely correct the concern, repeat Step 4 and index the shaft to the axle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 5840 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 5841 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: > 98-21-21 > Oct > 98 > Customer Interest for Drive/Propeller Shaft: > 98-25-21 > Dec > 98 > Exhaust System Cracks/Breaks Between Muffler/Tailpipe Drive/Propeller Shaft: Customer Interest Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: > 98-21-21 > Oct > 98 > Customer Interest for Drive/Propeller Shaft: > 98-18-7 > Sep > 98 > Steering/Driveline - High Speed Vibration Technical Service Bulletin # 98-18-7 Date: 980914 Steering/Driveline - High Speed Vibration Article No. 98-18-7 09/14/98 ^ STEERING COLUMN - HIGH SPEED VIBRATION - 4X4 VEHICLES EQUIPPED WITH COIL SUSPENSION ^ VIBRATION - HIGH SPEED VIBRATION - 4X4 VEHICLES EQUIPPED WITH COIL SUSPENSION LIGHT TRUCK: 1997-98 EXPEDITION 1998 NAVIGATOR This TSB article is being republished in its entirety to include the 1998 model year, revise the Service Procedure and include the latest level parts. ISSUE A vibration at highway speeds (approximately 97-113 km/h (60-70 mph)) may occur on some 4X4 vehicles with coil suspension. This vibration, present on cruise, however becomes more noticeable during coastdown. This may be caused by a driveline imbalance which produces a vibration in the seat, steering wheel, floorpan, and a rumble in the vehicle cabin. ACTION Refer to the following Service Procedure to determine the correct fix for the condition. PART NUMBER PART NAME F75Z-7H408-AA Transfer Case Output Plug XL1Z-4602-AA Driveshaft (5.4L Vehicles) XL1Z-4602-BA Driveshaft (4.6L vehicles) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-14-15 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:303000, 304000, 508000, 509000, 703000, 703300 Service Procedure 1. Drive the vehicle and verify the condition. Record all speeds, engine rpms and transmission gears that correspond to any boom, rumble or vibration that occurs. Note if the condition is cyclical, or if the condition severity changes by changing from 2H to AWD and 4H or by changing gears (3rd or OD), or the condition changes from cruise to coast and/or tip-in or tip-out. 2. Verify tire pressures are 207 kPa (30 psi) in the front tires and 241 kPa (35 psi) in the rear. If incorrect, correct tire pressure and redrive. If condition is not resolved, exchange all four tires with those of another Expedition or Navigator with same powertrain and wheel configuration which does not exhibit the condition. Redrive or properly calibrate wheel balancer and check the balance of the tires without removal of the factory weights. If tires are out of balance, rebalance and drive the vehicle. If the condition is not resolved, proceed to Step 3. 3. Both the driveshaft and the rear axle flange will have yellow paint dots. Verify that the driveshaft yellow dot and the rear axle flange yellow dot are aligned. If not aligned, rotate driveshaft at the rear axle flange so that the yellow dots are aligned and redrive. If the condition is still present, measure the driveshaft runout at both ends and in the middle. If the runout is over 0.030" at any location, replace the original double carden driveshaft with a new heavy duty single carden Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) and redrive. If the condition is still present, disconnect the driveshaft at the rear axle and measure the rear axle flange runout per the 1997 Expedition Workshop Manual, Page 205-00-25. If the flange runout is out of specification (spec is 0.011"), consult the Sterling Axle Plant Hotline at (800) FORD-AXL. Otherwise, proceed to Step 4. 4. Index the driveshaft in 90 degree increments around the rear axle flange and drive the vehicle after each reindexing. If condition is not resolved, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: > 98-21-21 > Oct > 98 > Customer Interest for Drive/Propeller Shaft: > 98-18-7 > Sep > 98 > Steering/Driveline - High Speed Vibration > Page 5855 reindex the driveshaft so that the yellow dot is aligned with the yellow dot on the rear axle flange and proceed to Step 5. NOTE AFTER CONDUCTING STEPS 1-4 AND ENSURING THAT THE CONDITION IS NOT ORIGINATING FROM THE TIRES/WHEELS AND/OR DRIVESHAFT, IT IS POSSIBLE THAT THE CONDITION COULD BE ORIGINATING FROM THE TRANSFER CASE. A TRANSFER CASE CONDITION IS TYPICALLY CHARACTERIZED BY A NOTICEABLE INCREASE IN THE SEVERITY OF THE VIBRATION FROM AN ACCELERATION/COAST TO A DECELERATION DRIVE MODE. IF THE VIBRATION CONDITION BEING EXPERIENCED IS SIMILAR TO THIS VIBRATION, COMPLETE STEPS 5-7 TO IDENTIFY IF THE TRANSFER CASE IS CONTRIBUTING TO THE CONDITION. 5. Transfer case testing is as follows: a. Index the rear driveshaft in 45 degree increments at the transfer case only (maintain the same alignment with the rear axle flange) and redrive between each index. Note if the condition severity changes. This process may reach a point where the vibration is eliminated and/or reduced to an acceptable level. Does the condition disappear or change significantly? ^ If yes, return vehicle to customer. ^ If no, or customer returns unsatisfied, proceed to Step 5b. NOTE THE TRANSFER CASE REAR OUTPUT MUST BE PLUGGED SO THAT FLUID DOES NOT SPILL DURING VEHICLE OPERATION. USE PLUG F75Z-7H408-AA. b. Completely remove the rear driveshaft from the vehicle and redrive in 4H mode so that the vehicle is being driven through the front driveshaft only. Does the condition disappear or change significantly? ^ If yes, proceed to Step 6. ^ If no, proceed to Step 7. 6. If not already done in Step 3, replace the carden rear driveshaft with a heavy duty single carden driveshaft (refer to Step 3). When installing the new driveshaft, be sure to align both the driveshaft and rear axle flange yellow paint dots. Redrive vehicle in 2H at highway speeds to verify the condition has disappeared or improved significantly. If the double carden driveshaft was replaced in Step 3, or after completing Step 6, the redrive resulted in little or no improvement, proceed to Step 7. NOTE REAR DRIVESHAFT REMOVAL IS FOR TEMPORARY TEST USE ONLY AND IS NOT RECOMMENDED FOR LONG DURATIONS OF TRAVEL. WHILE DRIVING IN THIS CONDITION, NOISE AND VIBRATIONS WILL BE EXPERIENCED AT VARIOUS SPEEDS THAT MAY NOT HAVE BEEN NOTED PREVIOUSLY. THE PURPOSE OF THIS TEST IS TO DETERMINE IF THE ORIGINAL CONDITION HAS BEEN CHANGED. 7. If the vehicle was built on or before 7/15/97, call the Transfer Case Hotline at (765) 286-6234 to request a certified transfer case. Calls to the hotline will be screened to ensure that the diagnosis in this TSB article has been followed thoroughly and properly. If your vehicle is a good candidate for a transfer case exchange, a certified transfer case will be shipped to your dealership. Install the certified transfer case into the vehicle and redrive. If the condition is not resolved, or the vehicle was built after 7/15/97, proceed to Step 8. 8. Call the Sterling Axle Plant Hotline at (800) FORD-AXL for a certified rear axle. If new axle does not completely correct the concern, repeat Step 4 and index the shaft to the axle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-25-21 > Dec > 98 > Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Drive/Propeller Shaft: All Technical Service Bulletins Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-18-7 > Sep > 98 > Steering/Driveline - High Speed Vibration Technical Service Bulletin # 98-18-7 Date: 980914 Steering/Driveline - High Speed Vibration Article No. 98-18-7 09/14/98 ^ STEERING COLUMN - HIGH SPEED VIBRATION - 4X4 VEHICLES EQUIPPED WITH COIL SUSPENSION ^ VIBRATION - HIGH SPEED VIBRATION - 4X4 VEHICLES EQUIPPED WITH COIL SUSPENSION LIGHT TRUCK: 1997-98 EXPEDITION 1998 NAVIGATOR This TSB article is being republished in its entirety to include the 1998 model year, revise the Service Procedure and include the latest level parts. ISSUE A vibration at highway speeds (approximately 97-113 km/h (60-70 mph)) may occur on some 4X4 vehicles with coil suspension. This vibration, present on cruise, however becomes more noticeable during coastdown. This may be caused by a driveline imbalance which produces a vibration in the seat, steering wheel, floorpan, and a rumble in the vehicle cabin. ACTION Refer to the following Service Procedure to determine the correct fix for the condition. PART NUMBER PART NAME F75Z-7H408-AA Transfer Case Output Plug XL1Z-4602-AA Driveshaft (5.4L Vehicles) XL1Z-4602-BA Driveshaft (4.6L vehicles) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-14-15 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:303000, 304000, 508000, 509000, 703000, 703300 Service Procedure 1. Drive the vehicle and verify the condition. Record all speeds, engine rpms and transmission gears that correspond to any boom, rumble or vibration that occurs. Note if the condition is cyclical, or if the condition severity changes by changing from 2H to AWD and 4H or by changing gears (3rd or OD), or the condition changes from cruise to coast and/or tip-in or tip-out. 2. Verify tire pressures are 207 kPa (30 psi) in the front tires and 241 kPa (35 psi) in the rear. If incorrect, correct tire pressure and redrive. If condition is not resolved, exchange all four tires with those of another Expedition or Navigator with same powertrain and wheel configuration which does not exhibit the condition. Redrive or properly calibrate wheel balancer and check the balance of the tires without removal of the factory weights. If tires are out of balance, rebalance and drive the vehicle. If the condition is not resolved, proceed to Step 3. 3. Both the driveshaft and the rear axle flange will have yellow paint dots. Verify that the driveshaft yellow dot and the rear axle flange yellow dot are aligned. If not aligned, rotate driveshaft at the rear axle flange so that the yellow dots are aligned and redrive. If the condition is still present, measure the driveshaft runout at both ends and in the middle. If the runout is over 0.030" at any location, replace the original double carden driveshaft with a new heavy duty single carden Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) and redrive. If the condition is still present, disconnect the driveshaft at the rear axle and measure the rear axle flange runout per the 1997 Expedition Workshop Manual, Page 205-00-25. If the flange runout is out of specification (spec is 0.011"), consult the Sterling Axle Plant Hotline at (800) FORD-AXL. Otherwise, proceed to Step 4. 4. Index the driveshaft in 90 degree increments around the rear axle flange and drive the vehicle after each reindexing. If condition is not resolved, Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-18-7 > Sep > 98 > Steering/Driveline - High Speed Vibration > Page 5865 reindex the driveshaft so that the yellow dot is aligned with the yellow dot on the rear axle flange and proceed to Step 5. NOTE AFTER CONDUCTING STEPS 1-4 AND ENSURING THAT THE CONDITION IS NOT ORIGINATING FROM THE TIRES/WHEELS AND/OR DRIVESHAFT, IT IS POSSIBLE THAT THE CONDITION COULD BE ORIGINATING FROM THE TRANSFER CASE. A TRANSFER CASE CONDITION IS TYPICALLY CHARACTERIZED BY A NOTICEABLE INCREASE IN THE SEVERITY OF THE VIBRATION FROM AN ACCELERATION/COAST TO A DECELERATION DRIVE MODE. IF THE VIBRATION CONDITION BEING EXPERIENCED IS SIMILAR TO THIS VIBRATION, COMPLETE STEPS 5-7 TO IDENTIFY IF THE TRANSFER CASE IS CONTRIBUTING TO THE CONDITION. 5. Transfer case testing is as follows: a. Index the rear driveshaft in 45 degree increments at the transfer case only (maintain the same alignment with the rear axle flange) and redrive between each index. Note if the condition severity changes. This process may reach a point where the vibration is eliminated and/or reduced to an acceptable level. Does the condition disappear or change significantly? ^ If yes, return vehicle to customer. ^ If no, or customer returns unsatisfied, proceed to Step 5b. NOTE THE TRANSFER CASE REAR OUTPUT MUST BE PLUGGED SO THAT FLUID DOES NOT SPILL DURING VEHICLE OPERATION. USE PLUG F75Z-7H408-AA. b. Completely remove the rear driveshaft from the vehicle and redrive in 4H mode so that the vehicle is being driven through the front driveshaft only. Does the condition disappear or change significantly? ^ If yes, proceed to Step 6. ^ If no, proceed to Step 7. 6. If not already done in Step 3, replace the carden rear driveshaft with a heavy duty single carden driveshaft (refer to Step 3). When installing the new driveshaft, be sure to align both the driveshaft and rear axle flange yellow paint dots. Redrive vehicle in 2H at highway speeds to verify the condition has disappeared or improved significantly. If the double carden driveshaft was replaced in Step 3, or after completing Step 6, the redrive resulted in little or no improvement, proceed to Step 7. NOTE REAR DRIVESHAFT REMOVAL IS FOR TEMPORARY TEST USE ONLY AND IS NOT RECOMMENDED FOR LONG DURATIONS OF TRAVEL. WHILE DRIVING IN THIS CONDITION, NOISE AND VIBRATIONS WILL BE EXPERIENCED AT VARIOUS SPEEDS THAT MAY NOT HAVE BEEN NOTED PREVIOUSLY. THE PURPOSE OF THIS TEST IS TO DETERMINE IF THE ORIGINAL CONDITION HAS BEEN CHANGED. 7. If the vehicle was built on or before 7/15/97, call the Transfer Case Hotline at (765) 286-6234 to request a certified transfer case. Calls to the hotline will be screened to ensure that the diagnosis in this TSB article has been followed thoroughly and properly. If your vehicle is a good candidate for a transfer case exchange, a certified transfer case will be shipped to your dealership. Install the certified transfer case into the vehicle and redrive. If the condition is not resolved, or the vehicle was built after 7/15/97, proceed to Step 8. 8. Call the Sterling Axle Plant Hotline at (800) FORD-AXL for a certified rear axle. If new axle does not completely correct the concern, repeat Step 4 and index the shaft to the axle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): Customer Interest Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 5874 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 5875 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 5881 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 5882 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve .................................................................................................................. .................................................. 7.75 Nm (68.6 Lb/In) Fuel Pressure Relief Valve Cap ..................... ........................................................................................................................................... 0.6 Nm (5.3 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Component Information > Specifications > Page 5885 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE 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. 1. Perform the fuel pressure release procedure. 2. Remove the (A) fuel pressure relief valve with the (B) fuel pressure relief valve cap. INSTALLATION 1. Install fuel pressure relief valve. 2. Install the fuel pressure relief valve cap. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect the battery ground cable. WARNING: THE BACKUP POWER SUPPLY ENERGY MUST BE DEPLETED BEFORE ANY AIR BAG COMPONENT REPAIR IS PERFORMED. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the driver side air bag module from the vehicle. WARNING: PLACE THE AIR BAG MODULE ON A BENCH WITH THE TRIM COVER FACING UP TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 4. Connect the air bag simulator to the vehicle harness at the top of the steering column. 5. Remove the passenger side air bag module from the vehicle. WARNING: PLACE THE AIR BAG MODULE ON A BENCH WITH THE DEPLOYMENT DOOR FACING UP TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 6. Connect the air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Reactivation Procedure 1. Disconnect the battery ground cable. WARNING: THE AIR BAG SIMULATORS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. In stall the driver side air bag module. 5. Remove the air bag simulator from the vehicle harness connector at the passenger side air bag module. 6. Install the passenger side air bag module. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 8. Prove out the system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > System Information > Service and Repair > Arming and Disarming > Page 5889 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Are both air bag sensors connected and mounted to the vehicle? [ ] 2. Is the three-way connector at the base of the steering column connected? [ ] 3. Are the air bag modules or air bag simulators connected? [ ] 4. Is the air bag diagnostic monitor connected? [ ] 5. Is the vehicle battery connected? [ ] Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Diagrams > Page 5893 Universal Joint: Description and Operation The universal joints (U-joints) connect to each end of the driveshaft and allow for up and down movement of the axles and transmission or transfer case. The U-joints are lubricated for the life of the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Double Cardan Universal Joint: Service and Repair Double Cardan DISASSEMBLY 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft in a vise or similar holding fixture. Place the driveshaft on a suitable workbench. 3. NOTE: If components are not marked and installed correctly, driveline imbalance can occur. Mark the positions of the driveshaft components. 4. Clamp the U-Joint Tool in a vise. 5. Remove the eight snap rings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Double Cardan > Page 5896 6. Remove the driveshaft slip yoke. 1 Position the driveshaft slip yoke in the U-Joint Tool. 2 Press out the bearing cups. 3 Remove the driveshaft slip yoke. 7. Press out the second set of bearing cups. 1 Position the driveshaft slip yoke in the U-Joint Tool. 2 Press out the bearing cup. 3 Rotate the driveshaft slip yoke. 4 Press out the remaining bearing cup. 8. Remove the centering cup spring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Double Cardan > Page 5897 9. Remove the driveshaft center yoke. 1 Position the driveshaft center yoke in the U-Joint Tool. 2 Press out the bearing cup. 3 Rotate the driveshaft center yoke. 4 Press out the remaining bearing cup. - Repeat to remove the spider from the driveshaft yoke. ASSEMBLY 1. Install a new bearing cup into the driveshaft yoke. 1 Start a new bearing cup into the driveshaft yoke. 2 Position the new spider in the driveshaft yoke. 3 Position the driveshaft in the U-Joint Tool. 4 Press the bearing cup below the yoke surface. - Repeat for the other side of the yoke. 2. Install the driveshaft center yoke. 1 Position the driveshaft center yoke in the U-Joint Tool. 2 Press in a new bearing cup. 3 Rotate the driveshaft center yoke. 4 Press in the other new bearing cup. 3. Install four new snap rings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Double Cardan > Page 5898 4. Install a new centering cup spring. 5. Install new bearing cups into the driveshaft yokes. 1 Start a new bearing cup into the driveshaft yoke. 2 Position the new spider in the driveshaft yoke. 3 Position the driveshaft in the U-Joint Tool. 4 Press the bearing cup below the yoke surface. 6. Install four new snap rings. 7. NOTE: Do not strike the bearings. Check the U-joints for freedom of movement. If bearings are binding, strike the yoke with a elastic hammer. 8. Install the driveshaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Double Cardan > Page 5899 Universal Joint: Service and Repair Single Cardan DISASSEMBLY 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft in the jaws of a vise or similar holding fixture. Place the driveshaft on a suitable workbench, being careful not to damage the tube. 3. NOTE: If components are not marked and therefore installed incorrectly, driveline imbalance can occur. Mark the positions of the driveshaft components. 4. Clamp the U-Joint Tool in a vise. 5. Remove the snap rings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Double Cardan > Page 5900 6. NOTE: If necessary, use a pair of pliers to remove a bearing cup if it cannot be pressed out all the way. Remove the driveshaft slip yoke. 1 Position the driveshaft slip yoke in the U-Joint Tool. 2 Press out a bearing cup. 3 Rotate the driveshaft slip yoke. 4 Press on the spider to remove the remaining bearing cup. 5 Remove the driveshaft slip yoke. 7. Repeat Step 6 to remove the remaining bearing cups, spiders and driveshaft flange yoke from the driveshaft. 8. Clean the yoke area at each end of the driveshaft. ASSEMBLY 1. Install the bearing cup. 1 Start a new bearing cup into the driveshaft yoke. 2 Position the new spider in the driveshaft yoke. 3 Position the driveshaft in the U-Joint Tool. 4 Press the bearing cup below the yoke surface. 2. NOTE: Use the yellow snap rings supplied in the kit to assemble the universal joint (U joint). If difficulty is encountered with the yellow snap rings, install the black snap rings. Remove the driveshaft from the U-Joint Tool, and install the snap ring. 3. Repeat Steps 1 and 2 for the opposite side of the driveshaft yoke. 4. Repeat Steps 1 through 3 to install the remaining new bearing cups, spider, driveshaft slip yoke, driveshaft flange yoke and snap rings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Double Cardan > Page 5901 5. NOTE: Do not strike the bearings. Check the U-joints for freedom of movement. If binding, strike the yoke with a brass or plastic hammer. 6. If necessary, use Premium Long-Life Grease XG-1-C or-K or equivalent meeting Ford Specification ESA-M1C75-B to lubricate the U-joints. 7. Install the driveshaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flywheel Bolts (Romeo Engines) 73-87 Nm (54-64 ft.lb) Flywheel Bolts (Windsor Engines) 73-87 Nm (54-64 ft.lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5905 Flex Plate: Service and Repair REMOVAL 1. Remove the transmission. Romeo Engines 2. On Romeo engines, remove the bolts. Windsor Engines 3. On Windsor engines, remove the bolts. INSTALLATION Romeo Engine Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5906 1. On Romeo engines position the flywheel, loosely install the bolts then tighten the bolts in the correct sequence. Windsor Engine 2. On Windsor engines position the flywheel, loosely install the bolts then tighten the bolts in the sequence shown. 3. Install the transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) AND TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The Transmission Control Switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the Transmission Control Indicator Lamp (TCIL) when the switch is off. The TCIL indicates overdrive cancel mode activated (lamp on) and Electronic Pressure Control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Overdrive Indicator Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the transmission external control. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart: 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5914 Overdrive Indicator Lamp: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5915 Overdrive Indicator Lamp: Pinpoint Tests Test D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5916 Test D1 - D2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5917 Test D3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the (D) position. - Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise ((D) position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumb wheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5933 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5934 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5935 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5936 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5937 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5938 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5939 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5940 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5941 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5942 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5943 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5944 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5945 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5946 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5947 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5948 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5949 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5950 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5951 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5952 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5953 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5954 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5955 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5956 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5957 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5958 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5959 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5960 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5961 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5962 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5963 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5964 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5965 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5966 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5967 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5968 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5969 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5970 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5971 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5972 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5973 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5974 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5975 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5976 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5977 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5978 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5979 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5980 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5981 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5982 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5983 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5984 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5985 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5986 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5987 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5988 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5989 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5990 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5991 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5992 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5993 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5994 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5995 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5996 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5997 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5998 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5999 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6001 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6002 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6003 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6004 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6005 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6006 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6007 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6008 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6009 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6010 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6011 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6012 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6013 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6014 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6015 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6016 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6017 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6018 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6019 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6020 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6021 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6022 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6023 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6024 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6025 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 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. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6026 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 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. 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 the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6027 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay Instrument Panel View The Torque On Demand Relay is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 6034 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay Instrument Panel View The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay Torque On Demand Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay > Page 6037 Transfer Case Shift Relays Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission > Page 6044 Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Page 6045 Overdrive Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) AND TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The Transmission Control Switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the Transmission Control Indicator Lamp (TCIL) when the switch is off. The TCIL indicates overdrive cancel mode activated (lamp on) and Electronic Pressure Control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Overdrive Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the transmission external control. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart: 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6048 Overdrive Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6049 Overdrive Switch: Pinpoint Tests Test C1 - C2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6050 Test C2 - C3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6051 Test C3 - C4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6052 Test C4 - C5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Page 6053 Overdrive Switch: Service and Repair REMOVAL 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS Transmission Range (TR) Sensor Bolts .................................................................................................................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 6057 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at the left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 6058 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 6059 Transmission Position Switch/Sensor: Description and Operation DIGITAL TRANSMISSION RANGE (TR) SENSOR The Digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in Park and Neutral, the back-up lamp circuit in Reverse and the neutral sense circuit (4x4 only) in Neutral. The digital TR sensor also opens and closes a set of four switches that are monitored by the powertrain control module to determine the position of the manual lever (P,R,N,D,2,1). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 6060 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Disconnect the digital TR electrical connector. 6. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 7. Loosen the digital TR bolts. 8. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 6061 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. 9. Tighten the bolts. 10. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 11. With the manual lever in overdrive connect the shift lever control cable. 12. Install the digital TR sensor electrical connector. 13. Lower the vehicle. 14. Connect the battery ground cable. 15. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Transmission Speed Sensor: Locations Transmission View The Output Shaft Speed Sensor is located at the left side of the transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Page 6065 Output Shaft Speed Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Page 6066 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED (OSS) SENSOR The Output Shaft Speed (OSS) sensor is a magnetic pickup, located at the output shaft ring gear, that sends a signal to the Powertrain Control Module (PCM) to indicate transmission output shaft speed. The OSS is used for torque converter clutch control, shift scheduling and to determine electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Temperature Sensor, Transmission Control Transmission Temperature Sensor/Switch: Description and Operation Temperature Sensor, Transmission Control TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR The Transmission Fluid Temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermister. It sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits Torque Converter Clutch (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Temperature Sensor, Transmission Control > Page 6071 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor/Switch, A/T TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR The Transmission Fluid Temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermister. It sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits Torque Converter Clutch (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications Gear Sensor/Switch: Specifications TORQUE SPECIFICATIONS Shift Range Selector Switch Screws ........................................................................................................................................... 2-3 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications > Page 6079 Gear Sensor/Switch: Service and Repair REMOVAL 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the shift range selector switch knob. 2 Disconnect the shift range selector switch electrical connector. 3 Remove the two shift range selector switch bolts. 4 Remove the shift range selector switch. INSTALLATION 1. Install the shift range selector switch. 1 Position the shift range selector switch. 2 Install the bolts. 3 Install the electrical connector. 4 Install the knob. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications > Page 6080 2. Install the center instrument panel trim panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Speed Sensor Bolt ........................................................................................................................................................... 3-6 Nm (27-53 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications TORQUE SPECIFICATIONS Shift Motor Bolts .................................................................................................................................. .................................... 8-11 Nm (71-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 6089 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 6090 Transfer Case Actuator: Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 6091 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 6092 Transfer Case Actuator: Description and Operation The shifting operation of the front drive axle is accomplished by activating the vacuum motor from a switch located on the instrument panel. It is recommended that shifting of the front axle should be done with the front wheels in a straight ahead position and during light throttle application. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor Transfer Case Actuator: Service and Repair Transfer Case Shift Motor REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the transfer case shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use proper electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 6095 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the four bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the electric shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 6096 Transfer Case Actuator: Service and Repair Vacuum Reservoir REMOVAL 1. Remove the right front fender splash shield. 1 Remove the screws. 2 Remove the pushpins. 3 Remove the right front fender splash shield. 2. Remove the engine vacuum reservoir. 1 Remove the bolts. 2 Disconnect the vacuum harness from the engine vacuum reservoir and remove the engine vacuum reservoir. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 6097 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 6098 Transfer Case Actuator: Service and Repair Auxiliary Vacuum Reservoir REMOVAL 1. Remove the front fender splash shield. 2. Disconnect the vacuum harness from the auxiliary vacuum reservoir and the A/C vacuum reservoir. 3. Slide the vacuum reservoir assembly out of the battery tray. 4. Separate the A/C vacuum reservoir from the auxiliary vacuum reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Component Information > Specifications > Capacity Specifications Differential: Capacity Specifications Please refer to Transfer Case Fluid; Specifications for the fluid capacity of the Transfer Case assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Component Information > Specifications > Capacity Specifications > Page 6103 Differential: Fluid Type Specifications TYPE .............................................................................................................................................................. MERCON(R) Automatic Transmission Fluid Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Capacity Transfer Case Fluid ............................................................................................................................. ...................................................................... 2.0 Qts Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 6108 Fluid - Transfer Case: Fluid Type Specifications TYPE .............................................................................................................................................................. MERCON(R) Automatic Transmission Fluid Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Page 6109 Fluid - Transfer Case: Service and Repair 1. CAUTION: If the proper fill procedures are not followed, transfer case failure can result. NOTE: Fluid level must be just below the fill plug. Remove the fill plug from the rear of the transfer case, and check fluid level. If the fluid is below the level, fill with Motorcraft MERCON(R) Automatic Transmission Fluid XT-2-QDX or -DDX or MERCON(R) equivalent. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay Instrument Panel View The Torque On Demand Relay is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 6117 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay Instrument Panel View The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay Torque On Demand Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay > Page 6120 Transfer Case Shift Relays Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications Gear Sensor/Switch: Specifications TORQUE SPECIFICATIONS Shift Range Selector Switch Screws ........................................................................................................................................... 2-3 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications > Page 6127 Gear Sensor/Switch: Service and Repair REMOVAL 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the shift range selector switch knob. 2 Disconnect the shift range selector switch electrical connector. 3 Remove the two shift range selector switch bolts. 4 Remove the shift range selector switch. INSTALLATION 1. Install the shift range selector switch. 1 Position the shift range selector switch. 2 Install the bolts. 3 Install the electrical connector. 4 Install the knob. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications > Page 6128 2. Install the center instrument panel trim panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Output Shaft: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting Output Shaft: Customer Interest MIL ON/DTC P0503/Erratic Speedometer/Shifting Article No. 98-5-8 03/16/98 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODE (DTC) P0503 STORED IN MEMORY - 4X4 VEHICLES ONLY ^ TRANSMISSION - SHIFT CONCERNS AND/OR ERRATIC SPEEDOMETER OPERATION MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - 4X4 VEHICLES ONLY LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to correct the parts listed. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P0503 may be stored in memory. There may also be transmission shift concerns and/or erratic speedometer operation. This may be caused by the speedometer drive gear being loose on the transfer case output shaft. ACTION: Replace the speedometer drive gear. The new gear has a tighter fit and should reduce the possibility of erratic signals. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 or 1998 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBDII) Service Manual. Service as required. 2. If no concerns were found or the concern is still present, replace the speedometer drive gear. 3. Remove the four (4) rear driveshaft flange bolts and remove the rear driveshaft. NOTE: TO MAINTAIN INITIAL DRIVESHAFT BALANCE, MARK THE REAR DRIVESHAFT YOKE AND AXLE FLANGE SO THEY CAN BE REASSEMBLED IN THEIR ORIGINAL POSITIONS. 4. Remove the six (6) extension housing bolts and remove the rear extension housing. 5. Remove the speedometer gear spacer then push the speedometer drive gear toward the transfer case and remove the steel ball. The speedometer drive gear can now be removed from the output shaft. 6. To install the revised Speedometer Drive Gear (F7TZ-17285-AA), reverse the removal procedure. NOTE: THE NEW SPEEDOMETER DRIVE GEAR WILL HAVE A SLIGHT INTERFERENCE FIT, HOWEVER IT WILL GO ON TO THE OUTPUT SHAFT BY HAND. DO NOT HEAT THE GEAR. 7. Before installing the extension housing, apply a small bead of sealant to the transfer case cover and extension housing mating surfaces. Use Ford Ultra Silicone Sealant (F7TZ-19554-AA or equivalent). 8. Top off transfer case with MERCON® (XT-2-QDX). PART NUMBER PART NAME F7IZ-19554-AA Ultra Silicone Sealant F7TZ-17285-AA Speedometer Drive Gear Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Output Shaft: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting > Page 6141 XT-2-QDX MERCON(R) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-3-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 980508A Replace Speedometer 0.8 Hr. Drive Gear DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 33 OASIS CODES: 204000, 204100, 204200, 206000, 501000, 501200, 502000, 508000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting Output Shaft: All Technical Service Bulletins MIL ON/DTC P0503/Erratic Speedometer/Shifting Article No. 98-5-8 03/16/98 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODE (DTC) P0503 STORED IN MEMORY - 4X4 VEHICLES ONLY ^ TRANSMISSION - SHIFT CONCERNS AND/OR ERRATIC SPEEDOMETER OPERATION MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - 4X4 VEHICLES ONLY LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to correct the parts listed. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P0503 may be stored in memory. There may also be transmission shift concerns and/or erratic speedometer operation. This may be caused by the speedometer drive gear being loose on the transfer case output shaft. ACTION: Replace the speedometer drive gear. The new gear has a tighter fit and should reduce the possibility of erratic signals. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 or 1998 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBDII) Service Manual. Service as required. 2. If no concerns were found or the concern is still present, replace the speedometer drive gear. 3. Remove the four (4) rear driveshaft flange bolts and remove the rear driveshaft. NOTE: TO MAINTAIN INITIAL DRIVESHAFT BALANCE, MARK THE REAR DRIVESHAFT YOKE AND AXLE FLANGE SO THEY CAN BE REASSEMBLED IN THEIR ORIGINAL POSITIONS. 4. Remove the six (6) extension housing bolts and remove the rear extension housing. 5. Remove the speedometer gear spacer then push the speedometer drive gear toward the transfer case and remove the steel ball. The speedometer drive gear can now be removed from the output shaft. 6. To install the revised Speedometer Drive Gear (F7TZ-17285-AA), reverse the removal procedure. NOTE: THE NEW SPEEDOMETER DRIVE GEAR WILL HAVE A SLIGHT INTERFERENCE FIT, HOWEVER IT WILL GO ON TO THE OUTPUT SHAFT BY HAND. DO NOT HEAT THE GEAR. 7. Before installing the extension housing, apply a small bead of sealant to the transfer case cover and extension housing mating surfaces. Use Ford Ultra Silicone Sealant (F7TZ-19554-AA or equivalent). 8. Top off transfer case with MERCON® (XT-2-QDX). PART NUMBER PART NAME F7IZ-19554-AA Ultra Silicone Sealant F7TZ-17285-AA Speedometer Drive Gear Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting > Page 6147 XT-2-QDX MERCON(R) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-3-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 980508A Replace Speedometer 0.8 Hr. Drive Gear DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 33 OASIS CODES: 204000, 204100, 204200, 206000, 501000, 501200, 502000, 508000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay Instrument Panel View The Torque On Demand Relay is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 6153 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay Instrument Panel View The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay Torque On Demand Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay > Page 6156 Transfer Case Shift Relays Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair Seals and Gaskets: Service and Repair Special Tools Special Tool REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Remove the rear driveshaft. 1 Remove the four rear driveshaft flange bolts. 2 Remove the rear driveshaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Page 6160 3. Remove the yoke to flange seal. - Use the Seal Remover and Slide Hammer. INSTALLATION 1. Install the yoke to flange seal. - Use the Seal Replacer. 2. Position the rear driveshaft and install the four rear driveshaft flange bolts. 3. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications Gear Sensor/Switch: Specifications TORQUE SPECIFICATIONS Shift Range Selector Switch Screws ........................................................................................................................................... 2-3 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications > Page 6168 Gear Sensor/Switch: Service and Repair REMOVAL 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the shift range selector switch knob. 2 Disconnect the shift range selector switch electrical connector. 3 Remove the two shift range selector switch bolts. 4 Remove the shift range selector switch. INSTALLATION 1. Install the shift range selector switch. 1 Position the shift range selector switch. 2 Install the bolts. 3 Install the electrical connector. 4 Install the knob. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications > Page 6169 2. Install the center instrument panel trim panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Speed Sensor Bolt ........................................................................................................................................................... 3-6 Nm (27-53 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Speed Sensor Bolt ........................................................................................................................................................... 3-6 Nm (27-53 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speedometer Gear, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Gear: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting Speedometer Gear: Customer Interest MIL ON/DTC P0503/Erratic Speedometer/Shifting Article No. 98-5-8 03/16/98 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODE (DTC) P0503 STORED IN MEMORY - 4X4 VEHICLES ONLY ^ TRANSMISSION - SHIFT CONCERNS AND/OR ERRATIC SPEEDOMETER OPERATION MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - 4X4 VEHICLES ONLY LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to correct the parts listed. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P0503 may be stored in memory. There may also be transmission shift concerns and/or erratic speedometer operation. This may be caused by the speedometer drive gear being loose on the transfer case output shaft. ACTION: Replace the speedometer drive gear. The new gear has a tighter fit and should reduce the possibility of erratic signals. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 or 1998 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBDII) Service Manual. Service as required. 2. If no concerns were found or the concern is still present, replace the speedometer drive gear. 3. Remove the four (4) rear driveshaft flange bolts and remove the rear driveshaft. NOTE: TO MAINTAIN INITIAL DRIVESHAFT BALANCE, MARK THE REAR DRIVESHAFT YOKE AND AXLE FLANGE SO THEY CAN BE REASSEMBLED IN THEIR ORIGINAL POSITIONS. 4. Remove the six (6) extension housing bolts and remove the rear extension housing. 5. Remove the speedometer gear spacer then push the speedometer drive gear toward the transfer case and remove the steel ball. The speedometer drive gear can now be removed from the output shaft. 6. To install the revised Speedometer Drive Gear (F7TZ-17285-AA), reverse the removal procedure. NOTE: THE NEW SPEEDOMETER DRIVE GEAR WILL HAVE A SLIGHT INTERFERENCE FIT, HOWEVER IT WILL GO ON TO THE OUTPUT SHAFT BY HAND. DO NOT HEAT THE GEAR. 7. Before installing the extension housing, apply a small bead of sealant to the transfer case cover and extension housing mating surfaces. Use Ford Ultra Silicone Sealant (F7TZ-19554-AA or equivalent). 8. Top off transfer case with MERCON® (XT-2-QDX). PART NUMBER PART NAME F7IZ-19554-AA Ultra Silicone Sealant F7TZ-17285-AA Speedometer Drive Gear Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speedometer Gear, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Gear: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting > Page 6184 XT-2-QDX MERCON(R) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-3-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 980508A Replace Speedometer 0.8 Hr. Drive Gear DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 33 OASIS CODES: 204000, 204100, 204200, 206000, 501000, 501200, 502000, 508000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speedometer Gear, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting Speedometer Gear: All Technical Service Bulletins MIL ON/DTC P0503/Erratic Speedometer/Shifting Article No. 98-5-8 03/16/98 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODE (DTC) P0503 STORED IN MEMORY - 4X4 VEHICLES ONLY ^ TRANSMISSION - SHIFT CONCERNS AND/OR ERRATIC SPEEDOMETER OPERATION MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - 4X4 VEHICLES ONLY LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to correct the parts listed. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P0503 may be stored in memory. There may also be transmission shift concerns and/or erratic speedometer operation. This may be caused by the speedometer drive gear being loose on the transfer case output shaft. ACTION: Replace the speedometer drive gear. The new gear has a tighter fit and should reduce the possibility of erratic signals. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 or 1998 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBDII) Service Manual. Service as required. 2. If no concerns were found or the concern is still present, replace the speedometer drive gear. 3. Remove the four (4) rear driveshaft flange bolts and remove the rear driveshaft. NOTE: TO MAINTAIN INITIAL DRIVESHAFT BALANCE, MARK THE REAR DRIVESHAFT YOKE AND AXLE FLANGE SO THEY CAN BE REASSEMBLED IN THEIR ORIGINAL POSITIONS. 4. Remove the six (6) extension housing bolts and remove the rear extension housing. 5. Remove the speedometer gear spacer then push the speedometer drive gear toward the transfer case and remove the steel ball. The speedometer drive gear can now be removed from the output shaft. 6. To install the revised Speedometer Drive Gear (F7TZ-17285-AA), reverse the removal procedure. NOTE: THE NEW SPEEDOMETER DRIVE GEAR WILL HAVE A SLIGHT INTERFERENCE FIT, HOWEVER IT WILL GO ON TO THE OUTPUT SHAFT BY HAND. DO NOT HEAT THE GEAR. 7. Before installing the extension housing, apply a small bead of sealant to the transfer case cover and extension housing mating surfaces. Use Ford Ultra Silicone Sealant (F7TZ-19554-AA or equivalent). 8. Top off transfer case with MERCON® (XT-2-QDX). PART NUMBER PART NAME F7IZ-19554-AA Ultra Silicone Sealant F7TZ-17285-AA Speedometer Drive Gear Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speedometer Gear, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting > Page 6190 XT-2-QDX MERCON(R) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-3-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 980508A Replace Speedometer 0.8 Hr. Drive Gear DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 33 OASIS CODES: 204000, 204100, 204200, 206000, 501000, 501200, 502000, 508000, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications TORQUE SPECIFICATIONS Shift Motor Bolts .................................................................................................................................. .................................... 8-11 Nm (71-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 6194 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 6195 Transfer Case Actuator: Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 6196 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 6197 Transfer Case Actuator: Description and Operation The shifting operation of the front drive axle is accomplished by activating the vacuum motor from a switch located on the instrument panel. It is recommended that shifting of the front axle should be done with the front wheels in a straight ahead position and during light throttle application. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor Transfer Case Actuator: Service and Repair Transfer Case Shift Motor REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the transfer case shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use proper electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 6200 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the four bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the electric shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 6201 Transfer Case Actuator: Service and Repair Vacuum Reservoir REMOVAL 1. Remove the right front fender splash shield. 1 Remove the screws. 2 Remove the pushpins. 3 Remove the right front fender splash shield. 2. Remove the engine vacuum reservoir. 1 Remove the bolts. 2 Disconnect the vacuum harness from the engine vacuum reservoir and remove the engine vacuum reservoir. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 6202 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 6203 Transfer Case Actuator: Service and Repair Auxiliary Vacuum Reservoir REMOVAL 1. Remove the front fender splash shield. 2. Disconnect the vacuum harness from the auxiliary vacuum reservoir and the A/C vacuum reservoir. 3. Slide the vacuum reservoir assembly out of the battery tray. 4. Separate the A/C vacuum reservoir from the auxiliary vacuum reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Description and Operation Pressure Regulating Solenoid: Description and Operation ELECTRONIC PRESSURE CONTROL (EPC) SOLENOID The Electronic Pressure Control (EPC) solenoid regulates transmission pressure. EPC valve pressure is used to control line pressure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Description and Operation > Page 6210 Pressure Regulating Solenoid: Service and Repair REMOVAL 1. Remove the manual control lever. 2. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on locking tabs to disconnect the sensors. Disconnect the molded lead frame from the sensors. 1 Disconnect the shift solenoid SSA/SS1 and SSB/SS2. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter connector. 3. Remove the EPC solenoid. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Description and Operation > Page 6211 1. Install the EPC solenoid. 2. Connect the molded lead frame to the sensors. - Connect the bulkhead inter connector. - Connect the Electronic Pressure Control (EPC) solenoid. - Connect the Torque Converter Clutch (TCC). - Connect the shift solenoid SSA/SS1 and SSB/SS2. 3. Install the manual control lever. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications TORQUE SPECIFICATIONS Brake Shift Interlock Solenoid Bolts ........................................................................................................................................ 7-11 Nm (63-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 6215 Shift Interlock Solenoid: Service and Repair REMOVAL 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation Shift Solenoid: Description and Operation Part 1 Of 2 Part 2 Of 2 SHIFT SOLENOID-SSA/SS1 AND SSB/SS2 Two on/off shift solenoids provide gear selection of first through fourth gears by controlling the pressure to the three shift valves. One unit containing the two shift solenoids is located in the main control valve body. The shift solenoids are two-way normally open style. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TORQUE SPECIFICATIONS TCC Solenoid Bolt ............................................................................................................................... .................................. 9-11 Nm (80-100 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6222 Torque Converter Clutch Solenoid: Description and Operation Part 1 Of 2 Part 2 Of 2 The Torque Converter Clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications TORQUE SPECIFICATIONS Shift Motor Bolts .................................................................................................................................. .................................... 8-11 Nm (71-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 6227 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 6228 Transfer Case Actuator: Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 6229 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 6230 Transfer Case Actuator: Description and Operation The shifting operation of the front drive axle is accomplished by activating the vacuum motor from a switch located on the instrument panel. It is recommended that shifting of the front axle should be done with the front wheels in a straight ahead position and during light throttle application. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor Transfer Case Actuator: Service and Repair Transfer Case Shift Motor REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the transfer case shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use proper electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 6233 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the four bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the electric shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 6234 Transfer Case Actuator: Service and Repair Vacuum Reservoir REMOVAL 1. Remove the right front fender splash shield. 1 Remove the screws. 2 Remove the pushpins. 3 Remove the right front fender splash shield. 2. Remove the engine vacuum reservoir. 1 Remove the bolts. 2 Disconnect the vacuum harness from the engine vacuum reservoir and remove the engine vacuum reservoir. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 6235 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 6236 Transfer Case Actuator: Service and Repair Auxiliary Vacuum Reservoir REMOVAL 1. Remove the front fender splash shield. 2. Disconnect the vacuum harness from the auxiliary vacuum reservoir and the A/C vacuum reservoir. 3. Slide the vacuum reservoir assembly out of the battery tray. 4. Separate the A/C vacuum reservoir from the auxiliary vacuum reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) AND TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The Transmission Control Switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the Transmission Control Indicator Lamp (TCIL) when the switch is off. The TCIL indicates overdrive cancel mode activated (lamp on) and Electronic Pressure Control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Overdrive Indicator Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the transmission external control. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart: 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6244 Overdrive Indicator Lamp: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6245 Overdrive Indicator Lamp: Pinpoint Tests Test D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6246 Test D1 - D2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6247 Test D3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the (D) position. - Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise ((D) position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumb wheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay Instrument Panel View The Torque On Demand Relay is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 6264 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay Instrument Panel View The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay Torque On Demand Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay > Page 6267 Transfer Case Shift Relays Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission > Page 6274 Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Page 6275 Overdrive Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) AND TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The Transmission Control Switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the Transmission Control Indicator Lamp (TCIL) when the switch is off. The TCIL indicates overdrive cancel mode activated (lamp on) and Electronic Pressure Control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Testing and Inspection > Initial Inspection and Diagnostic Overview Overdrive Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the transmission external control. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart: 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6278 Overdrive Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6279 Overdrive Switch: Pinpoint Tests Test C1 - C2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6280 Test C2 - C3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6281 Test C3 - C4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6282 Test C4 - C5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Testing and Inspection > Page 6283 Overdrive Switch: Service and Repair REMOVAL 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS Transmission Range (TR) Sensor Bolts .................................................................................................................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 6287 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at the left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 6288 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 6289 Transmission Position Switch/Sensor: Description and Operation DIGITAL TRANSMISSION RANGE (TR) SENSOR The Digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in Park and Neutral, the back-up lamp circuit in Reverse and the neutral sense circuit (4x4 only) in Neutral. The digital TR sensor also opens and closes a set of four switches that are monitored by the powertrain control module to determine the position of the manual lever (P,R,N,D,2,1). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 6290 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. If equipped, turn the air suspension switch OFF. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the manual lever shift control cable. 5. Disconnect the digital TR electrical connector. 6. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 7. Loosen the digital TR bolts. 8. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Specifications > Page 6291 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. 9. Tighten the bolts. 10. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 11. With the manual lever in overdrive connect the shift lever control cable. 12. Install the digital TR sensor electrical connector. 13. Lower the vehicle. 14. Connect the battery ground cable. 15. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Transmission Speed Sensor: Locations Transmission View The Output Shaft Speed Sensor is located at the left side of the transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Page 6295 Output Shaft Speed Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 > Page 6296 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED (OSS) SENSOR The Output Shaft Speed (OSS) sensor is a magnetic pickup, located at the output shaft ring gear, that sends a signal to the Powertrain Control Module (PCM) to indicate transmission output shaft speed. The OSS is used for torque converter clutch control, shift scheduling and to determine electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Temperature Sensor, Transmission Control Transmission Temperature Sensor/Switch: Description and Operation Temperature Sensor, Transmission Control TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR The Transmission Fluid Temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermister. It sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits Torque Converter Clutch (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Temperature Sensor, Transmission Control > Page 6301 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor/Switch, A/T TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR The Transmission Fluid Temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermister. It sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits Torque Converter Clutch (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications Gear Sensor/Switch: Specifications TORQUE SPECIFICATIONS Shift Range Selector Switch Screws ........................................................................................................................................... 2-3 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications > Page 6309 Gear Sensor/Switch: Service and Repair REMOVAL 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the shift range selector switch knob. 2 Disconnect the shift range selector switch electrical connector. 3 Remove the two shift range selector switch bolts. 4 Remove the shift range selector switch. INSTALLATION 1. Install the shift range selector switch. 1 Position the shift range selector switch. 2 Install the bolts. 3 Install the electrical connector. 4 Install the knob. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Specifications > Page 6310 2. Install the center instrument panel trim panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Speed Sensor Bolt ........................................................................................................................................................... 3-6 Nm (27-53 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations > Page 6319 Power Distribution Relay Box The 4 Wheel Anti-Lock Brake System Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Differential Speed Sensor > Component Information > Locations Differential Speed Sensor: Locations Body View The Differential Speed Sensor is located on the rear axle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored Electronic Brake Control Module: Customer Interest ABS - Lamp ON/DTC B1342 Stored Article No. 98-9-15 05/11/98 ^ BRAKES - 4WABS - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL VEHICLES BUILT THROUGH 2/12/98 ^ LAMP - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL - VEHICLES BUILT THROUGH 2/12/98 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B1342 may be stored in memory and/or New Generation Star (NGS) Tester may read "Invalid Code." This may be caused by the Nonvolatile Random Access Memory (NVRAM) chip inside the anti-lock brake control module not resetting at low residual voltages. ABS brake function may become inoperative, however, normal braking operation will be maintained. ACTION Replace the anti-lock brake control module. Modules with a build date of 2/19/98 or later have been revised to incorporate a new NVRAM chip. Refer to the appropriate Workshop Manual, Section 206-09, for replacement procedures. PART NUMBER PART NAME F75Z-2C065-AA Anti-lock Brake Control Module (F-150) F75Z-20065-BA Anti-lock Brake Control Module (F-250 LD) F7SZ-2C065-CA Anti-lock Brake Control Module (Expedition, Navigator) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980915A Diagnose And Replace 0.6 Hr. ABS Module - F-Series, Expedition, And Navigator DEALER CODING CONDITION BASIC PART NO. CODE 2C065 42 OASIS CODES: 206000, 301000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored Electronic Brake Control Module: All Technical Service Bulletins ABS - Lamp ON/DTC B1342 Stored Article No. 98-9-15 05/11/98 ^ BRAKES - 4WABS - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL VEHICLES BUILT THROUGH 2/12/98 ^ LAMP - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL - VEHICLES BUILT THROUGH 2/12/98 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B1342 may be stored in memory and/or New Generation Star (NGS) Tester may read "Invalid Code." This may be caused by the Nonvolatile Random Access Memory (NVRAM) chip inside the anti-lock brake control module not resetting at low residual voltages. ABS brake function may become inoperative, however, normal braking operation will be maintained. ACTION Replace the anti-lock brake control module. Modules with a build date of 2/19/98 or later have been revised to incorporate a new NVRAM chip. Refer to the appropriate Workshop Manual, Section 206-09, for replacement procedures. PART NUMBER PART NAME F75Z-2C065-AA Anti-lock Brake Control Module (F-150) F75Z-20065-BA Anti-lock Brake Control Module (F-250 LD) F7SZ-2C065-CA Anti-lock Brake Control Module (Expedition, Navigator) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980915A Diagnose And Replace 0.6 Hr. ABS Module - F-Series, Expedition, And Navigator DEALER CODING CONDITION BASIC PART NO. CODE 2C065 42 OASIS CODES: 206000, 301000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6336 Electronic Brake Control Module: Specifications TORQUE SPECIFICATIONS Control Module Screws .............................................................................................................................................................. 4-5 Nm (36-44 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6337 Electronic Brake Control Module: Locations Engine View The 4 Wheel Anti-Lock Brake System Module is located at the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6338 Electronic Brake Control Module: Diagrams 4 Wheel Anti - Lock Brake System Module ( C146) 4 Wheel Anti - Lock Brake System Module (C147) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6339 Electronic Brake Control Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the two anti-lock brake control module electrical connectors. 3. Disconnect the pump motor electrical connector from the ABS module. 4. Remove the anti-lock brake control module. 1 Remove the screws. 2 Remove the anti-lock brake control module. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6340 1. To install, reverse the removal procedure. CAUTION: Ensure that the replacement anti-lock brake control module identification sticker reads EXP. Use of any other module could result in diminished ABS performance. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications TORQUE SPECIFICATIONS EHCU Bolts To Lower Bracket ................................................................................................................................................. 30-40 Nm (23-29 ft. lbs.) EHCU Bracket Bolts To Frame ................................................................................................................................................. 17-23 Nm (13-16 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6344 Hydraulic Control Assembly - Antilock Brakes: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connectors. 3. Disconnect the hydraulic brake lines. 1 Disconnect the two inlet hydraulic brake lines. 2 Disconnect the three outlet hydraulic brake lines. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: Plug each open port to prevent brake fluid from spilling. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6345 4. Remove the electronic hydraulic control unit (EHCU). 1 Remove the bolts. 2 Remove the EHCU. 5. If necessary, remove the EHCU bracket. 1 Remove the bolts. 2 Remove the EHCU bracket. INSTALLATION 1. If removed, install the EHCU bracket. 1 Position the bracket. 2 Install the EHCU bracket bolts. 2. Install the EHCU. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6346 1 Position the EHCU. 2 Install the bolts. 3. Connect the hydraulic brake lines. CAUTION: Only authorized Ford inlet hydraulic brake lines should be used. These lines are of specific design and should only be replaced with authorized Ford parts. 4. Connect the two anti-lock brake control module electrical connectors. 5. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km/h (10 mi) or more to relearn the strategy. 6. Bleed the brake hydraulic system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front Anti-Lock Brake Sensor Bolt 63-80 in.lb Front ABS Sensor Wire Bracket Bolt 62-80 in.lb Rear Anti-Lock Brake Sensor Bolt 25-29 ft.lb Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring Wheel Speed Sensor: Service and Repair Toothed Ring Rear The rear sensor indicator is built into the rear differential. Refer to rear differential for disassembly and assembly procedures. Removal and Installation The front anti-lock brake sensor indicator is integral to the front wheel hub. If the indicator is bad, the wheel hub must be replaced. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 6352 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Front REMOVAL 1. Disconnect the front anti-lock brake sensor electrical connector. 2. Remove the front disc brake rotor shield. 3. Remove the (A) two front anti-lock brake sensor bolts and the (B) front anti-lock brake sensor. INSTALLATION 1. To install, reverse the removal procedure. Rear REMOVAL 1. Remove the rear anti-lock brake sensor. 1 Disconnect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 6353 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. NOTE: Remove all dirt from the mounting surface and sensor to prevent contamination of rear axle lubrication. INSTALLATION 1. Clean and inspect the rear anti-lock brake sensor. 1 Clean the axle mounting surface. 2 Inspect and clean the magnetized rear anti-lock brake sensor pole piece. 3 Inspect the rear anti-lock brake sensor O-ring for damage. Replace if necessary. 4 Lightly lubricate the rear anti-lock brake sensor O-ring with Synthetic SAE 75W-140 Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. CAUTION: Use care not to get dirt in the rear axle housing. 2. Install the rear anti-lock brake sensor. 1 Position the rear anti-lock brake sensor and install the rear anti-lock brake sensor bolt. NOTE: Do not apply force to the plastic rear anti-lock brake sensor connector. 2 Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding Brake Bleeding: Service and Repair Gravity Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. - 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 replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. - When the brake master cylinder has been replaced or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT3 fluid meeting Ford specification ESA-M6C25-A. 2. Bleed the rear disc brake calipers. 1 Place a box end wrench on the RH rear disc brake caliper bleeder screw. 2 Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3 Open the bleeder screw and leave open until clear bubble-free brake fluid flows. Repeat for LH rear disc brake caliper. 3. Tighten the rear disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6358 4. Bleed the front disc brake calipers. 1 Place a box end wrench on the RH front disc brake caliper bleeder screw. 2 Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3 Open the bleeder screw and leave open until clear bubble-free brake fluid flows. - Repeat for LH front disc brake caliper. 5. Tighten the front disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6359 Brake Bleeding: Service and Repair Manual Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. - 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 replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6360 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 7. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat Steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6361 Brake Bleeding: Service and Repair Master Cylinder Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR IS MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system - 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 replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Disconnect the brake master cylinder outlet tubes. NOTE: When the brake master cylinder has been replaced or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. 2. Install short brake tubes with ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes without air bubbles. 4. Remove the short brake tubes and install the brake outlet tubes. 5. Bleed each brake tube at the brake master cylinder as follows: 1 Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2 Loosen the rearmost brake tube fittings until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6362 6. While the assistant maintains pressure on the brake pedal, tighten the brake tubes. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6363 Brake Bleeding: Service and Repair Pressure Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. - 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 replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. - 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. Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. 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. 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6364 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. 8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6365 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (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. 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. - 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 replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. - This procedure only needs to be performed if the 4 wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been replaced. - 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. - Performing the NGS program routine drives entrapped air from the otherwise inaccessible lower section of the 4WABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleedings remove the air from the system. - Add recommended brake fluid as necessary throughout the procedure. 1. Connect a clear waste line to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with recommended brake fluid. 2. With the RH rear disc brake caliper bleeder screw open, cycle the brake pedal until no more air is seen in the waste line. 3. Tighten the RH rear disc brake caliper bleeder screw and disconnect the waste line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6366 4. Repeat steps 1, 2, and 3 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. 5. Connect the NGS DCL cable adapter into the vehicle data link connector (DLC) under the dash and follow the NGS instructions. 6. Repeat the conventional bleed procedure as outlined in Steps 1 through 4. 7. If the brake pedal feels spongy, repeat the NGS service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Page 6367 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications TORQUE SPECIFICATIONS Brake Pedal Bracket Nuts and Bolt ............................................................................................................................................ 22-28 Nm (17-20 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 6371 Brake Pedal Assy: Service and Repair REMOVAL 1. Disconnect the brake master cylinder push rod. 1 Remove the self-locking pin. 2 Remove the brake master cylinder push rod spacer. 3 Separate the stoplight switch from the brake booster push rod. 4 Remove the brake master cylinder push rod bushing Remove Brake Pedal Assembly 2. Remove the one brake pedal bracket bolt and the four brake pedal bracket nuts and remove the brake pedal assembly. CAUTION: Support the brake master cylinder and power brake booster In the engine compartment. INSTALLATION Install Brake Pedal Assembly 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Testing and Inspection Brake Warning Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Front Caliper Bleeder Screw 9-13 ft.lb Caliper Bolts 21-26 ft.lb Caliper Anchor Plate Bolts 126-169 ft.lb Rear Caliper Bleeder Screw 12-18 ft.lb Brake Caliper Bolts 20 ft.lb Disc Brake Adapter Nuts 40 ft.lb Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 6379 Brake Caliper: Description and Operation The disc brake caliper: - is a pin slider, dual piston type. - has two caliper pistons. - housing has a fluid inlet at the center of the bore. A square section seal fitted into an annular groove in the caliper cylinder bore seals against hydraulic pressure, while rubber boots seal the caliper pistons and caliper bore from contamination. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate Brake Caliper: Service and Repair Anchor Plate REMOVAL 1. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1 Remove the two front disc brake caliper anchor plate bolts. 2 Remove the front disc brake caliper anchor plate. INSTALLATION 1. Install the front disc brake caliper anchor plate. 1 Position the front disc brake caliper anchor plate. 2 Install the front disc brake caliper anchor plate bolts. 2. Install the pads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6382 Brake Caliper: Service and Repair Front Disassembly and Assembly DISASSEMBLY 1. Remove the disc brake caliper. 2. Drain the remaining brake fluid from the disc brake caliper. 3. Secure the disc brake caliper in a vise. 4. Remove the caliper pistons. 1 Place a block of wood between the caliper bridge and the caliper pistons. 2 Apply low air pressure to the fluid port in the disc brake caliper. 3 Force out the caliper pistons to the block of wood. 4 Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. 6. If the cylinder bores are excessively scored or corroded, replace the disc brake caliper. NOTE: Do not hone the cylinder bores. Pistons are not available for honed cylinder bores. ASSEMBLY Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6383 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 High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Install the caliper pistons. 1 Install the piston seal. 2 Install the piston boot on the caliper piston. 3 Insert the caliper piston. CAUTION: Be careful not to damage or dislodge the piston seal. 4 Press the caliper piston into the cylinder bore. CAUTION: Be careful not to cock the caliper piston. 3. Install the disc brake caliper. Removal and Installation REMOVAL WARNING: - ASBESTOS FIBER DUST MAY BE PRESENT ON BRAKE AND CLUTCH ASSEMBLIES AND IS HAZARDOUS TO HEALTH IF INHALED. - BRAKE AND CLUTCH ASSEMBLIES SHOULD BE CLEANED USING A VACUUM CLEANER RECOMMENDED FOR USE WITH ASBESTOS FIBERS SUCH AS BRAKE/CLUTCH/SERVICE VACUUM. THE BAG MUST BE LABELED PER OSHA INSTRUCTIONS, SEALED, AND THE TRASH HAULER NOTIFIED AS TO THE BAG'S CONTENTS. - IF A VACUUM SUITABLE FOR ASBESTOS IS NOT AVAILABLE, CLEANING SHOULD BE DONE WET. IF DUST GENERATION IS STILL POSSIBLE, TECHNICIANS SHOULD WEAR GOVERNMENT-APPROVED TOXIC DUST PURIFYING RESPIRATORS. - OCCUPATIONAL HEALTH AND SAFETY ACT (OSHA) REQUIRES AREAS WHERE ASBESTOS DUST GENERATION IS POSSIBLE TO BE ISOLATED AND POSTED WITH WARNING SIGNS. ONLY TECHNICIANS PERFORMING BRAKE OR CLUTCH REPAIR SHOULD BE PRESENT IN THE AREA. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6384 1. Loosen the lug nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. 2. Raise and support the vehicle. 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. 3. Remove the wheel and tire assembly. 1 Remove the lug nuts. 2 Remove the wheel and tire assembly. 4. Inspect the pads for wear or contamination. CAUTION: Replace the lining if worn to or past the specified thickness above the metal backing plate or rivets. Replace the pads in complete axle sets. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6385 5. Disconnect the front brake hose. 1 Remove the front brake hose bolt. 2 Disconnect the front brake hose. 3 Remove the copper washers. Plug the front brake hose. 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. 6. Remove the disc brake caliper. 1 Remove the two caliper bolts using a T45 Torx. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate. 7. Measure the front disc brake rotor thickness. - Replace the front disc brake rotor if not within specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6386 8. Inspect the disc brake caliper for leaks. - If leaks are found, disassembly is required. INSTALLATION 1. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the front disc brake caliper bolts. 2. Install the front brake hose. - Use new copper washers to connect the front brake hose. Install the front brake hose bolt. 3. Bleed the front disc brake caliper. 4. Clean the wheel hub mounting surface. WARNING: ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL PRESENT ON THE MOUNTING SURFACES OF THE WHEEL OR THE SURFACE OF THE WHEEL HUB, BRAKE DRUM OR FRONT DISC BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUTS TO LOOSEN AND COULD ALLOW THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6387 Wheel And Tire Assembly - Lug Nut Tightening Specification 5. Install the tire and wheel assembly. 6. Install the center cap. 7. Inspect the brake operation. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6388 Brake Caliper: Service and Repair Rear Adapter REMOVAL 1. Disconnect the parking brake rear cable and conduit. 2. Remove the axle shaft. 3. Remove the parking brake shoe and linings. 4. Remove the nuts and the rear wheel disc brake adapter. INSTALLATION 1. Follow the removal procedure in reverse order. Disassembly and Assembly 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6389 5. Remove and discard the piston seal and dust boot. NOTE: Do not hone the cylinder bore. Caliper pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore is excessively scored or corroded, replace the rear disc brake caliper. 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 High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. Cylinder bore. - Piston seal. - Caliper piston. - Dust boot. 2. Install the piston seal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6390 3. Install the dust boot. 4. Install the caliper piston. CAUTION: Be careful not to damage or dislodge the piston seal. 5. Install the rear disc brake caliper. Removal and Installation REMOVAL WARNING: - ASBESTOS FIBER DUST MAY BE PRESENT ON BRAKE AND CLUTCH ASSEMBLIES AND IS HAZARDOUS TO HEALTH IF INHALED. - BRAKE AND CLUTCH ASSEMBLIES SHOULD BE CLEANED USING A VACUUM CLEANER RECOMMENDED FOR USE WITH ASBESTOS FIBERS, SUCH AS A BRAKE/CLUTCH/SERVICE VACUUM. THE BAG MUST BE LABELED PER OSHA INSTRUCTIONS, SEALED, AND THE TRASH HAULER NOTIFIED AS TO THE BAG'S CONTENTS. - IF A VACUUM SUITABLE FOR ASBESTOS IS NOT AVAILABLE, CLEANING SHOULD BE DONE WET. IF DUST GENERATION IS STILL POSSIBLE? TECHNICIANS SHOULD WEAR GOVERNMENT-APPROVED TOXIC DUST PURIFYING RESPIRATORS. - OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA) REQUIRES AREAS WHERE ASBESTOS DUST GENERATION IS POSSIBLE TO BE ISOLATED AND POSTED WITH WARNING SIGNS. ONLY TECHNICIANS PERFORMING BRAKE OR CLUTCH REPAIR SHOULD BE PRESENT IN THE AREA. 1. Raise and support the vehicle. 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. 2. Remove the wheel and tire assembly. 3. Inspect the brake pads for wear or contamination. - Replace the brake pads if worn to or past specification. CAUTION: Replace the brake pads in complete axle sets. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6391 4. Disconnect the brake hose. 1 Remove the bolt. 2 Disconnect the rear wheel brake hose. 3 Remove the copper washers, and plug the brake hose. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 5. Remove the rear disc brake caliper. 1 Remove the brake caliper bolts. 2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. At the time of publication there are no approved materials or procedures for relubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. 6. Inspect the rear disc brake caliper for leaks. - If leaks are found, disassembly is required. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6392 7. Measure the rear disc brake rotor thickness. - Replace the rear disc brake rotor if not within specification. INSTALLATION 1. Install the rear disc brake caliper. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: - Make sure the stainless steel shoe slippers are correctly positioned. Replace if worn or damaged. - When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. 2. Install the rear wheel brake hose. - Use new copper washers; connect the brake hose and install the caliper flow bolt. 3. Bleed the rear disc brake caliper. 4. Clean the wheel hub mounting surface. WARNING: ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL PRESENT ON THE MOUNTING SURFACES OF THE WHEEL, WHEEL HUB, OR DISC BRAKE ROTOR. ANY DEBRIS ON THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUTS TO LOOSEN AND COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. 5. Install the wheel and tire assembly. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6393 6. Verify proper brake operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Page 6394 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Brake and Rotor - Service Tips Brake Pad: Technical Service Bulletins Brake and Rotor - Service Tips Article No. 97-19-4 09/15/97 BRAKES - BRAKE AND ROTOR SERVICE TIPS FORD: 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1994-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR 1993-98 RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION ISSUE: This TSB article is intended to give a technician information regarding brake repairs to help reduce unnecessary repairs. ACTION: Refer to the following list when performing brake repairs. ^ Where rotors are the causal part, linings should only be replaced if they are damaged, e.g., cracked, taper wear, heavily grooved, etc., or if specifically instructed in a TSB. ^ Where linings are the causal part, rotors should not be machined unless they are heavily grooved or if specifically instructed in a TSB. Other exceptions would include instances where the non-causal parts are found to be below minimum serviceable thickness or if the technician estimates that the parts will not last until the next service interval. Since these parts are classified as wear items (such as: linings, pads, rotors, and drums) replacement is not covered under warranty. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 6399 Brake Pad: Specifications Min. Thickness Above Backing Plate Or Rivets 0.039 in Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 6400 Brake Pad: Description and Operation The pads are: - contained within the front disc brake caliper anchor plate. - held to the front disc brake caliper anchor plate abutments by disc brake anti-rattle clips. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front REMOVAL WARNING: - ASBESTOS FIBER DUST MAY BE PRESENT ON BRAKE AND CLUTCH ASSEMBLIES AND IS HAZARDOUS TO HEALTH IF INHALED. - BRAKE AND CLUTCH ASSEMBLIES SHOULD BE CLEANED USING A VACUUM CLEANER RECOMMENDED FOR USE WITH ASBESTOS FIBERS. THE BAG MUST BE LABELED PER OSHA INSTRUCTIONS, SEALED, AND THE TRASH HAULER NOTIFIED AS TO THE BAG'S CONTENTS. - IF A VACUUM SUITABLE FOR ASBESTOS IS NOT AVAILABLE, CLEANING SHOULD BE DONE WET. IF DUST GENERATION IS STILL POSSIBLE, TECHNICIANS SHOULD WEAR GOVERNMENT-APPROVED TOXIC DUST PURIFYING RESPIRATORS. - OCCUPATIONAL HEALTH AND SAFETY ACT (OSHA) REQUIRES AREAS WHERE ASBESTOS DUST GENERATION IS POSSIBLE TO BE ISOLATED AND POSTED WITH WARNING SIGNS. ONLY TECHNICIANS PERFORMING BRAKE OR CLUTCH REPAIR SHOULD BE PRESENT IN THE AREA. 1. Loosen the lug nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. 2. Raise and support the vehicle. 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. 3. Remove the wheel and tire assembly. 1 Remove the lug nuts. 2 Remove the wheel and tire assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6403 4. Inspect the pads for wear or contamination. CAUTION: Replace the lining if worn to or past the specified thickness above the metal backing plate or rivets. Replace the pads in complete axle sets. 5. Remove the disc brake caliper. 1 Remove the caliper bolts using a T45 Torx. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate. CAUTION: When removing the front disc brake caliper, never allow it to hang from a brake hose. Provide a suitable support. 6. Measure the front disc brake rotor thickness. - Replace the front disc brake rotor if not within specification. 7. Inspect the disc brake caliper for leaks. - If leaks are found, disassembly is required. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6404 8. Remove the disc brake anti-rattle clips. 1 Remove the pads. 2 Remove the disc brake anti-rattle clips. INSTALLATION 1. Install the pads. 1 Install the disc brake anti-rattle clips. 2 Install the pads. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the front brake pad lining material. Do not install contaminated pads. 2. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the disc brake caliper bolts. CAUTION: Use care not to damage the bleeder screw or front wheel disc brake shield. 3. Clean the wheel hub mounting surface. WARNING: ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL PRESENT ON THE MOUNTING SURFACES OF THE WHEEL OR THE SURFACE OF THE WHEEL HUB, BRAKE DRUM OR FRONT DISC BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUTS TO LOOSEN AND COULD ALLOW THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6405 Wheel And Tire Assembly - Lug Nut Tightening Specification 4. Install the tire and wheel assembly. 5. Install the center cap. 6. Inspect the brake operation. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6406 Brake Pad: Service and Repair Rear REMOVAL 1. Remove the rear disc brake caliper. NOTE: It is not necessary to remove the hydraulic brake line when performing this procedure. 2. Remove the brake pads. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the brake pads. 3. Retract the caliper piston into the rear disc brake caliper. 4. Remove the slippers. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6407 1. Install the slippers. 2. Install the brake pads. CAUTION: The brake pads should be replaced in full axle sets only. Do not replace the worn brake pads on only one side of the vehicle. 3. Install the rear disc brake caliper. 4. Verify proper brake operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment Technical Service Bulletin # 98-5A-5 Date: 980318 Hub-Mount Brake Rotor Machining Equipment Article No. 98-5A-5 03/18/98 ^ BRAKES - AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT ^ BRAKE ROTOR MACHINING - AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1993-98 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE: Hub-mount brake rotor machining equipment from Rotunda is now approved for warranty and service use. Brake roughness consists of one or more of the following symptoms while braking: ^ Steering wheel vibration/nibble ^ vibration ^ Brake pedal pulsation Brake roughness is caused by: ^ Uneven rotor wear known as Disc Thickness Variation (DTV). DTV is caused by excessive Lateral Run-Out (LRO) or overtorqued wheel lug nuts ^ Non-uniform lining transfer ACTION: Use Rotunda Hub-Mount Lathe / Pro-Cut (201-00002) to service vehicles with brake roughness. The hub-mount lathe removes DTV, lining transfer, and on-vehicle rotor LRO. The hub-mount lathe has the following advantages over caliper-mount lathes: ^ Improved rotor LRO and "dishing" tolerances ^ Ability to machine rear rotors on live axles, except for trucks with dual rear wheels ^ Easier set-up Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 6412 Refer to the Service Procedure for details. PART NUMBER PART NAME F6AZ-9L494-AA High Temperature Nickel Anti-Seize Lubricant OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-4-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 702300, 703000, 703400 Service Procedure 1. Verify concern. 2. Pre-checks to include: ^ Check OASIS and TSBs for vehicle-specific brake/vibration concerns ^ Visually inspect suspension bushings/ball joints ^ Visually inspect tire conditions and pressure ^ Check wheel bearing end-play 3. Remove wheel/tire. 4. Remove caliper. 5. For vehicles with two-piece hub/rotor: a. Mark rotor and wheel stud for proper indexing during reassembly. b. Remove rotor. NOTE: THE ROTOR MUST HAVE SUFFICIENT THICKNESS AFTER MACHINING TO BE OVER THE MINIMUM THICKNESS SPECIFICATION C 6. Measure rotor thickness and record measurement. Replace rotor if below the minimum thickness specification cast in the rotor. CAUTION: DO NOT USE ABRASIVE SANDING DISC SINCE IT WILL REMOVE METAL FROM MOUNTING SURFACES AND ADVERSELY AFFECT 7. Remove corrosion from wheel mounting surface, both rotor mounting surfaces, and hub mounting surface. A die grinder with a Scotchbrite(R) surfa 8. For vehicles with two-piece hub/rotor, reinstall rotor onto hub, aligning with marks from Step 5a. NOTE: READ THE ENTIRE OPERATING MANUAL AND VIEW THE VIDEO SHIPPED WITH THE LATHE BEFORE INSTALLING, OPERATING, OR SERVICING THE LATHE. 9. Machine rotors using the Rotunda Hub-Mount Brake Lathe / Pro-Cut (201-00002). a. Install hub adapter and silencer belt (where applicable). b. Install cutting lathe. NOTE: TOTAL INDICATED READING (TIR) TARGET IS 0.000 mm, MAXIMUM IS O.O6 mm (0.003"). c. Adjust lathe oscillation using a dial indicator. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 6413 NOTE: DEPTH OF CUT SHOULD BE BETWEEN 0.10 AND O.2O mm (0.004 AND 0.008"). LIGHTER CUTS WILL CAUSE THE BIT TO HEAT UP A d. Center cutting head, adjust cutting bits, install chip deflector. e. Machine rotor. f. Measure and record rotor thickness. NOTE: TARGET LRO IS 0.000 mm, MAXIMUM IS O.05 mm (0.002"). g. Install dial indicator, measure and record rotor LRO. Remove dial indicator. h. Remove lathe and silencer belt. 10. Remove metal shavings. 11. Remove the adapter. 12. For vehicles with two-piece hub/rotors: a. Remove rotor from hub. b. Remove metal shavings from hub and rotor mounting surfaces and from ABS sensors. c. Apply High Temperature Nickel Anti-Seize Lubricant (F6AZ-9L494-AA) to hub mounting surface to prevent future corrosion. d. Match marks on rotor and hub and assemble rotor to hub. 13. Install pads and calipers. NOTE: USING AN IMPACT TOOL WITHOUT AN ACCUTORO(R) SOCKET WILL LEAD TO UNEVENLY TORQUED LUG NUTS. THIS CAUSES ROTOR 14. Install wheels using impact guns equipped with Rotunda AccuTorq(R) sockets. Use a torque wrench on locking lug nuts. 15. Check brake operation before returning to customer. Support Telephone Numbers 1. Lathe Administration Support: (800) 768-8632 2. Pro-Cut Technical Support: (800) 543-6618 Reference list for Pro-Cut car labor operations: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 6414 ^ A = Aspire ^ B = Escort/Tracer ^ C = Probe ^ D = Contour/Mystique ^ E = Mustang ^ F = Taurus/Sable ^ G = Thunderbird/Cougar ^ H = Crown Victoria/Grand Marquis ^ I = Continental ^ J = Mark VIII ^ K = Town Car ^ L = Festiva ^ M = Tempo/Topaz Reference list for Pro-Cut light truck labor operations: ^ AA = Villager ^ AB = Windstar ^ AC = Aerostar 4X2 ^ AD = Aerostar 4X4 ^ AE = Ranger 4X2 ^ AF = Ranger 4X4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 6415 ^ AG = Explorer/Mountaineer 4X2 ^ AH = Explorer/Mountaineer 4X4 ^ AI = Econoline ^ AJ = F-250 HD/F-350 4X2 ^ AK = F-250 HD/F-350 4X4 ^ AL = F-Super Duty ^ AM = F-150/F-250 LD 4X2 ^ AN = F-150/F-250 LD 4X4 And Bronco ^ AO = Expedition/Navigator 4X2 ^ AP = Expedition/Navigator 4X4 ^ AQ = Super Duty F Series Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 6416 Brake Rotor/Disc: Technical Service Bulletins Brake and Rotor - Service Tips Article No. 97-19-4 09/15/97 BRAKES - BRAKE AND ROTOR SERVICE TIPS FORD: 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1994-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR 1993-98 RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION ISSUE: This TSB article is intended to give a technician information regarding brake repairs to help reduce unnecessary repairs. ACTION: Refer to the following list when performing brake repairs. ^ Where rotors are the causal part, linings should only be replaced if they are damaged, e.g., cracked, taper wear, heavily grooved, etc., or if specifically instructed in a TSB. ^ Where linings are the causal part, rotors should not be machined unless they are heavily grooved or if specifically instructed in a TSB. Other exceptions would include instances where the non-causal parts are found to be below minimum serviceable thickness or if the technician estimates that the parts will not last until the next service interval. Since these parts are classified as wear items (such as: linings, pads, rotors, and drums) replacement is not covered under warranty. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 6417 Brake Rotor/Disc: Technical Service Bulletins Brake Rotor - Incorrect Discard Thickness Specification Article No. 99-25-6 12/13/99 ^ BRAKES - INCORRECT ROTOR THICKNESS STAMPED ON ROTOR - F-150 4X2 ONLY ^ BRAKES - INCORRECT WORKSHOP MANUAL ROTOR DISCARD THICKNESS SPECIFICATION FORD: 1997-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-2000 NAVIGATOR ISSUE The 1997-2000 Workshop Manuals do not provide the correct and complete specification for rotor discard thickness. Additionally, some 4X2 F-150 rotors may have an incorrect rotor discard thickness stamped on them. Updated Information Per TSB 99-25-6 ACTION Refer to the Front and Rear Disc Rotor Discard Specification Charts for correct rotor discard specification. * SOME 4X2 F-150 ROTORS SHOW "24.7 mm" PRINTED ON THE ROTOR BACK SIDE. THIS IS AN ERROR, THESE CAN BE CUT TO 24.5 mm DISCARD THICKNESS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 390000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc Brake Rotor/Disc: Specifications Brake Rotor/Disc Front Min. Disc Thickness (Discard Thickness) 1.09 in Rear Brake Disc Min. Thickness 0.47 in Max. Brake Disc Runout 0.0002 in Max. Brake Disc Thickness Variation 0.0005 in Front Min. Disc Thickness (Discard Thickness) 1.09 in Rear Brake Disc Min. Thickness 0.47 in Max. Brake Disc Runout 0.0002 in Max. Brake Disc Thickness Variation 0.0005 in Front Min. Disc Thickness (Discard Thickness) 1.09 in Rear Brake Disc Min. Thickness 0.75 in Max. Brake Disc Runout 0.0002 in Max. Brake Disc Thickness Variation 0.0005 in Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc > Page 6420 Brake Rotor/Disc: Specifications Disc Backing Plate TORQUE SPECIFICATIONS Brake Disc Shield Screws ..................................................................................................................................................... 10-14 Nm (89-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 6421 Brake Rotor/Disc: Description and Operation The front disc brake rotor shield: - bolts to the front wheel knuckle. - protects the bearings and inboard surface of the front disc brake rotor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc Brake Rotor/Disc: Service and Repair Brake Rotor/Disc Front REMOVAL 1. Remove the front disc brake caliper anchor plate. 2. Remove the front disc brake rotor. - If necessary, resurface the front disc brake rotor. Ford recommends on-vehicle rotor machining. Follow the lathe manufacturer's instructions. INSTALLATION 1. Position the front disc brake rotor. 1 Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent. Clean the front disc brake rotor. 2 Position the front disc brake rotor. 2. Install the front disc brake caliper anchor plate. Rear REMOVAL 1. Remove the rear disc brake caliper. NOTE: When removing the rear disc brake caliper in this procedure, it is not necessary to disconnect the rear wheel brake hose. 2. Remove the rear disc brake rotor. 1 Remove the press-on keeper nuts, if so equipped. 2 Remove the rear disc brake rotor. NOTE: If the rear disc brake rotor binds on the parking brake shoe and lining, remove the adjustment hole access plug and contract the parking brake shoe and lining. 3. Inspect the rear disc brake rotor. - Replace the rear disc brake rotor if not within specification. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 6424 1. Install the rear disc brake rotors 2. Install the rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 6425 Brake Rotor/Disc: Service and Repair Disc Backing Plate Front REMOVAL 1. Remove the rotor. 2. Remove the wheel hub. 3. Remove the front disc brake rotor shield. 1 Remove the front disc brake rotor shield screws. 2 Remove the front disc brake rotor shield. INSTALLATION 1. Follow the removal procedure in reverse order. Rear REMOVAL 1. Remove the rear wheel disc brake adapter. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 6426 2. Remove the rear wheel disc brake shield. 1 Drill out the rivets. 2 Remove the rear wheel disc brake shield. INSTALLATION 1. Seal the rivet holes with Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A, and install the rear wheel disc brake shield. NOTE: Because the rear wheel disc brake shield is held in position by the four rear wheel disc brake adapter bolts, new rivets are not required. 2. Install the rear wheel disc brake adapter. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding Brake Bleeding: Service and Repair Gravity Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. - 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 replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. - When the brake master cylinder has been replaced or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT3 fluid meeting Ford specification ESA-M6C25-A. 2. Bleed the rear disc brake calipers. 1 Place a box end wrench on the RH rear disc brake caliper bleeder screw. 2 Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3 Open the bleeder screw and leave open until clear bubble-free brake fluid flows. Repeat for LH rear disc brake caliper. 3. Tighten the rear disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6432 4. Bleed the front disc brake calipers. 1 Place a box end wrench on the RH front disc brake caliper bleeder screw. 2 Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3 Open the bleeder screw and leave open until clear bubble-free brake fluid flows. - Repeat for LH front disc brake caliper. 5. Tighten the front disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6433 Brake Bleeding: Service and Repair Manual Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. - 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 replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6434 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 7. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat Steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6435 Brake Bleeding: Service and Repair Master Cylinder Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR IS MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system - 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 replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Disconnect the brake master cylinder outlet tubes. NOTE: When the brake master cylinder has been replaced or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. 2. Install short brake tubes with ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes without air bubbles. 4. Remove the short brake tubes and install the brake outlet tubes. 5. Bleed each brake tube at the brake master cylinder as follows: 1 Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2 Loosen the rearmost brake tube fittings until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6436 6. While the assistant maintains pressure on the brake pedal, tighten the brake tubes. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6437 Brake Bleeding: Service and Repair Pressure Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. - 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 replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. - 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. Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. 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. 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6438 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. 8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6439 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (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. 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. - 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 replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. - This procedure only needs to be performed if the 4 wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been replaced. - 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. - Performing the NGS program routine drives entrapped air from the otherwise inaccessible lower section of the 4WABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleedings remove the air from the system. - Add recommended brake fluid as necessary throughout the procedure. 1. Connect a clear waste line to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with recommended brake fluid. 2. With the RH rear disc brake caliper bleeder screw open, cycle the brake pedal until no more air is seen in the waste line. 3. Tighten the RH rear disc brake caliper bleeder screw and disconnect the waste line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 6440 4. Repeat steps 1, 2, and 3 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. 5. Connect the NGS DCL cable adapter into the vehicle data link connector (DLC) under the dash and follow the NGS instructions. 6. Repeat the conventional bleed procedure as outlined in Steps 1 through 4. 7. If the brake pedal feels spongy, repeat the NGS service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Page 6441 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Front Caliper Bleeder Screw 9-13 ft.lb Caliper Bolts 21-26 ft.lb Caliper Anchor Plate Bolts 126-169 ft.lb Rear Caliper Bleeder Screw 12-18 ft.lb Brake Caliper Bolts 20 ft.lb Disc Brake Adapter Nuts 40 ft.lb Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 6445 Brake Caliper: Description and Operation The disc brake caliper: - is a pin slider, dual piston type. - has two caliper pistons. - housing has a fluid inlet at the center of the bore. A square section seal fitted into an annular groove in the caliper cylinder bore seals against hydraulic pressure, while rubber boots seal the caliper pistons and caliper bore from contamination. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate Brake Caliper: Service and Repair Anchor Plate REMOVAL 1. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1 Remove the two front disc brake caliper anchor plate bolts. 2 Remove the front disc brake caliper anchor plate. INSTALLATION 1. Install the front disc brake caliper anchor plate. 1 Position the front disc brake caliper anchor plate. 2 Install the front disc brake caliper anchor plate bolts. 2. Install the pads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6448 Brake Caliper: Service and Repair Front Disassembly and Assembly DISASSEMBLY 1. Remove the disc brake caliper. 2. Drain the remaining brake fluid from the disc brake caliper. 3. Secure the disc brake caliper in a vise. 4. Remove the caliper pistons. 1 Place a block of wood between the caliper bridge and the caliper pistons. 2 Apply low air pressure to the fluid port in the disc brake caliper. 3 Force out the caliper pistons to the block of wood. 4 Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. 6. If the cylinder bores are excessively scored or corroded, replace the disc brake caliper. NOTE: Do not hone the cylinder bores. Pistons are not available for honed cylinder bores. ASSEMBLY Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6449 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 High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Install the caliper pistons. 1 Install the piston seal. 2 Install the piston boot on the caliper piston. 3 Insert the caliper piston. CAUTION: Be careful not to damage or dislodge the piston seal. 4 Press the caliper piston into the cylinder bore. CAUTION: Be careful not to cock the caliper piston. 3. Install the disc brake caliper. Removal and Installation REMOVAL WARNING: - ASBESTOS FIBER DUST MAY BE PRESENT ON BRAKE AND CLUTCH ASSEMBLIES AND IS HAZARDOUS TO HEALTH IF INHALED. - BRAKE AND CLUTCH ASSEMBLIES SHOULD BE CLEANED USING A VACUUM CLEANER RECOMMENDED FOR USE WITH ASBESTOS FIBERS SUCH AS BRAKE/CLUTCH/SERVICE VACUUM. THE BAG MUST BE LABELED PER OSHA INSTRUCTIONS, SEALED, AND THE TRASH HAULER NOTIFIED AS TO THE BAG'S CONTENTS. - IF A VACUUM SUITABLE FOR ASBESTOS IS NOT AVAILABLE, CLEANING SHOULD BE DONE WET. IF DUST GENERATION IS STILL POSSIBLE, TECHNICIANS SHOULD WEAR GOVERNMENT-APPROVED TOXIC DUST PURIFYING RESPIRATORS. - OCCUPATIONAL HEALTH AND SAFETY ACT (OSHA) REQUIRES AREAS WHERE ASBESTOS DUST GENERATION IS POSSIBLE TO BE ISOLATED AND POSTED WITH WARNING SIGNS. ONLY TECHNICIANS PERFORMING BRAKE OR CLUTCH REPAIR SHOULD BE PRESENT IN THE AREA. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6450 1. Loosen the lug nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. 2. Raise and support the vehicle. 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. 3. Remove the wheel and tire assembly. 1 Remove the lug nuts. 2 Remove the wheel and tire assembly. 4. Inspect the pads for wear or contamination. CAUTION: Replace the lining if worn to or past the specified thickness above the metal backing plate or rivets. Replace the pads in complete axle sets. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6451 5. Disconnect the front brake hose. 1 Remove the front brake hose bolt. 2 Disconnect the front brake hose. 3 Remove the copper washers. Plug the front brake hose. 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. 6. Remove the disc brake caliper. 1 Remove the two caliper bolts using a T45 Torx. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate. 7. Measure the front disc brake rotor thickness. - Replace the front disc brake rotor if not within specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6452 8. Inspect the disc brake caliper for leaks. - If leaks are found, disassembly is required. INSTALLATION 1. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the front disc brake caliper bolts. 2. Install the front brake hose. - Use new copper washers to connect the front brake hose. Install the front brake hose bolt. 3. Bleed the front disc brake caliper. 4. Clean the wheel hub mounting surface. WARNING: ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL PRESENT ON THE MOUNTING SURFACES OF THE WHEEL OR THE SURFACE OF THE WHEEL HUB, BRAKE DRUM OR FRONT DISC BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUTS TO LOOSEN AND COULD ALLOW THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6453 Wheel And Tire Assembly - Lug Nut Tightening Specification 5. Install the tire and wheel assembly. 6. Install the center cap. 7. Inspect the brake operation. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6454 Brake Caliper: Service and Repair Rear Adapter REMOVAL 1. Disconnect the parking brake rear cable and conduit. 2. Remove the axle shaft. 3. Remove the parking brake shoe and linings. 4. Remove the nuts and the rear wheel disc brake adapter. INSTALLATION 1. Follow the removal procedure in reverse order. Disassembly and Assembly 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6455 5. Remove and discard the piston seal and dust boot. NOTE: Do not hone the cylinder bore. Caliper pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore is excessively scored or corroded, replace the rear disc brake caliper. 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 High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. Cylinder bore. - Piston seal. - Caliper piston. - Dust boot. 2. Install the piston seal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6456 3. Install the dust boot. 4. Install the caliper piston. CAUTION: Be careful not to damage or dislodge the piston seal. 5. Install the rear disc brake caliper. Removal and Installation REMOVAL WARNING: - ASBESTOS FIBER DUST MAY BE PRESENT ON BRAKE AND CLUTCH ASSEMBLIES AND IS HAZARDOUS TO HEALTH IF INHALED. - BRAKE AND CLUTCH ASSEMBLIES SHOULD BE CLEANED USING A VACUUM CLEANER RECOMMENDED FOR USE WITH ASBESTOS FIBERS, SUCH AS A BRAKE/CLUTCH/SERVICE VACUUM. THE BAG MUST BE LABELED PER OSHA INSTRUCTIONS, SEALED, AND THE TRASH HAULER NOTIFIED AS TO THE BAG'S CONTENTS. - IF A VACUUM SUITABLE FOR ASBESTOS IS NOT AVAILABLE, CLEANING SHOULD BE DONE WET. IF DUST GENERATION IS STILL POSSIBLE? TECHNICIANS SHOULD WEAR GOVERNMENT-APPROVED TOXIC DUST PURIFYING RESPIRATORS. - OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA) REQUIRES AREAS WHERE ASBESTOS DUST GENERATION IS POSSIBLE TO BE ISOLATED AND POSTED WITH WARNING SIGNS. ONLY TECHNICIANS PERFORMING BRAKE OR CLUTCH REPAIR SHOULD BE PRESENT IN THE AREA. 1. Raise and support the vehicle. 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. 2. Remove the wheel and tire assembly. 3. Inspect the brake pads for wear or contamination. - Replace the brake pads if worn to or past specification. CAUTION: Replace the brake pads in complete axle sets. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6457 4. Disconnect the brake hose. 1 Remove the bolt. 2 Disconnect the rear wheel brake hose. 3 Remove the copper washers, and plug the brake hose. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 5. Remove the rear disc brake caliper. 1 Remove the brake caliper bolts. 2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. At the time of publication there are no approved materials or procedures for relubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. 6. Inspect the rear disc brake caliper for leaks. - If leaks are found, disassembly is required. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6458 7. Measure the rear disc brake rotor thickness. - Replace the rear disc brake rotor if not within specification. INSTALLATION 1. Install the rear disc brake caliper. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: - Make sure the stainless steel shoe slippers are correctly positioned. Replace if worn or damaged. - When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. 2. Install the rear wheel brake hose. - Use new copper washers; connect the brake hose and install the caliper flow bolt. 3. Bleed the rear disc brake caliper. 4. Clean the wheel hub mounting surface. WARNING: ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL PRESENT ON THE MOUNTING SURFACES OF THE WHEEL, WHEEL HUB, OR DISC BRAKE ROTOR. ANY DEBRIS ON THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUTS TO LOOSEN AND COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. 5. Install the wheel and tire assembly. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 6459 6. Verify proper brake operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Page 6460 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. High Performance DOT3 Brake Fluid Ford Specification ESA-M6C25-A Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6467 Brake Fluid Level Sensor/Switch: Description and Operation The brake fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) or secondary (rear) system will cause this system to activate. If the brake fluid level warning switch is inoperative, the brake master cylinder reservoir must be replaced. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Hose Brake Hose/Line: Specifications Brake Hose TORQUE SPECIFICATIONS Front Brake Hose Bolt ......................................................................................................................... ...................................... 30-40 Nm (23-29 ft. lbs.) Brake Hose Bracket To Front Suspension Lower Arm Screw .................................................................................................................................... 13-17 Nm (10-13 ft. lbs.) Rear Caliper Flow Bolt .............................................................................................................................................................. 30-40 Nm (23-29 ft. lbs.) Left Rear Brake Hose Bracket Bolt ........................................................................................................................................... 13-17 Nm (10-12 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Hose > Page 6472 Brake Hose/Line: Specifications Brake Line TORQUE SPECIFICATIONS 1/2-20 And 9/16-18 Brake Lines ................................................................................................................................................ 21-29 Nm (15-21 ft. lbs.) 7/16-24 Brake Lines ............................................................................................... .................................................................... 15-20 Nm (11-14 ft. lbs.) Front Master Cylinder Brake Tube ............................................................................................................................................ 22-28 Nm (17-20 ft. lbs.) Rear Master Cylinder Brake Tube ............................................................................................................................................. 15-20 Nm (11-14 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Brake Hose Brake Hose/Line: Description and Operation Brake Hose CAUTION: Only Ford authorized inlet hydraulic brake tubes should be used. These tubes are of a specific design and should be replaced with Ford authorized parts only. Steel tubing with flex hoses are used in the hydraulic lines between the brake master cylinder and the hydraulic control unit. Steel tubing is used between the hydraulic control unit and the front and rear hoses. Double flared brake tubing should provide good leakproof connections. When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After replacement, bleed the brake system. The wet appearance on the outer cover of rubber brake hoses is called "sweating." This is a normal condition for neoprene rayon braid hose and is not a sign of leakage or cause for replacement of the hose. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Brake Hose > Page 6475 Brake Hose/Line: Description and Operation Brake Line CAUTION: Only Ford authorized inlet hydraulic brake tubes should be used. These tubes are of a specific design and should be replaced with Ford authorized parts only. Steel tubing with flex hoses are used in the hydraulic lines between the brake master cylinder and the hydraulic control unit. Steel tubing is used between the hydraulic control unit and the front and rear hoses. Double flared brake tubing should provide good leakproof connections. When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After replacement, bleed the brake system. The wet appearance on the outer cover of rubber brake hoses is called "sweating." This is a normal condition for neoprene rayon braid hose and is not a sign of leakage or cause for replacement of the hose. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications Brake Proportioning/Combination Valve: Specifications TORQUE SPECIFICATIONS Brake Master Cylinder Fluid Control Valve .............................................................................................................................. 30-49 Nm (22-36 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 6479 Brake Proportioning/Combination Valve: Description and Operation Brake Master Cylinder Fluid Control Valve The brake master cylinder fluid control valve regulates the hydraulic pressure in the rear brake system. It is located on the brake master cylinder and is screwed into the rearmost outlet port. When the brake pedal is applied, the full brake pressure passes through the brake master cylinder fluid control valve to the rear brake system until the valves split point is reached. Above its split point, the brake master cylinder fluid control valve begins to reduce the hydraulic pressure to the rear brakes, creating a balanced braking condition between the front and rear wheels to minimize rear wheel lockup during hard braking. In the case of front brake system malfunction, the brake master cylinder fluid control valve has a bypass feature which allows full hydraulic pressure to the rear brake system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 6480 Brake Proportioning/Combination Valve: Service and Repair REMOVAL WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. Remove Brake Master Cylinder Fluid Control Valve 1. Remove the brake master cylinder fluid control valve. 1 Disconnect and plug the brake line. 2 Remove the brake master cylinder fluid control valve NOTE: Do not attempt to service the control valve It is serviced only as an assembly. INSTALLATION Install Brake Master Cylinder Fluid Control Valve 1. Follow the removal procedure in reverse order. - Bleed the rear brakes. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications TORQUE SPECIFICATIONS EHCU Bolts To Lower Bracket ................................................................................................................................................. 30-40 Nm (23-29 ft. lbs.) EHCU Bracket Bolts To Frame ................................................................................................................................................. 17-23 Nm (13-16 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6484 Hydraulic Control Assembly - Antilock Brakes: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connectors. 3. Disconnect the hydraulic brake lines. 1 Disconnect the two inlet hydraulic brake lines. 2 Disconnect the three outlet hydraulic brake lines. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: Plug each open port to prevent brake fluid from spilling. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6485 4. Remove the electronic hydraulic control unit (EHCU). 1 Remove the bolts. 2 Remove the EHCU. 5. If necessary, remove the EHCU bracket. 1 Remove the bolts. 2 Remove the EHCU bracket. INSTALLATION 1. If removed, install the EHCU bracket. 1 Position the bracket. 2 Install the EHCU bracket bolts. 2. Install the EHCU. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6486 1 Position the EHCU. 2 Install the bolts. 3. Connect the hydraulic brake lines. CAUTION: Only authorized Ford inlet hydraulic brake lines should be used. These lines are of specific design and should only be replaced with authorized Ford parts. 4. Connect the two anti-lock brake control module electrical connectors. 5. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km/h (10 mi) or more to relearn the strategy. 6. Bleed the brake hydraulic system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications TORQUE SPECIFICATIONS Brake Master Cylinder Nuts ....................................................................................................................................................... 22-28 Nm (17-20 ft. lbs.) Front Master Cylinder Brake Line ............................................................................................................................................ 22-28 Nm (17-20 ft. lbs.) Rear Master Cylinder Brake Line .............................................................................................................................................. 15-20 Nm (11-14 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 6490 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 6491 Brake Master Cylinder: Description and Operation The brake master cylinder is a dual-piston type. The brake master cylinder is assisted by a power brake booster. The following conditions are considered normal, and are not indications that the brake master cylinder is in need of repair or replacement: - Low brake fluid level detected without signs of leakage. This condition is caused by displacement of brake fluid from the brake master cylinder reservoir into the disc brake calipers to compensate for normal brake wear. Add brake fluid as needed. - A momentary or slight ripple of brake fluid inside the brake master cylinder reservoir upon application or release of the brake pedal. - A trace of brake fluid found on the outside of the power brake booster below the brake master cylinder mounting flange. This condition results from the lubricating action of the brake master cylinder wiping seal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Brake Master Cylinder: Initial Inspection and Diagnostic Overview NORMAL CONDITIONS The following conditions are considered normal and are not indications that the brake master cylinder is in need of service. Condition 1: During normal operation of the brake master cylinder, the fluid level in the brake master cylinder reservoir will rise during brake application and fall during release. The net fluid level (i.e., after brake application and release) will remain unchanged. Condition 2: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange. This results from the normal lubricating action of the master cylinder bore and seal. Condition 3: Fluid level will decrease with pad wear. ABNORMAL CONDITIONS Changes in brake pedal feel or travel are indicators that something could be wrong in the brake system. Refer to the symptom chart for abnormal condition diagnosis. See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptom Chart(s) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6494 Brake Master Cylinder: Component Tests and General Diagnostics Bypass Conditions Test 1. Disconnect the brake lines at the brake master cylinder. 2. Plug the outlet ports of the brake master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and must be rebuilt or replaced. Compensator Port Test 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 6495 Brake Master Cylinder: Adjustments 1. Remove the brake master cylinder. 2. Adjust the power brake booster to brake master cylinder push rod length. 1 Measure the power brake booster to brake master cylinder push rod. 2 If necessary, adjust the screw to the proper length. 3. Install the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir Brake Master Cylinder: Service and Repair Brake Fluid Reservoir REMOVAL WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. 1. Disconnect the battery ground cable. 2. Disconnect the brake master cylinder fluid level warning switch electrical connector. 3. Use a suitable suction device to drain the brake master cylinder reservoir. Do not reuse the drained fluid. 4. Carefully pry up on the brake master cylinder reservoir to remove. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6498 1. Install the brake master cylinder reservoir. 1 Lubricate the two grommets with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A, and insert the grommets in the brake master cylinder. 2 Press the brake master cylinder reservoir into the grommets until it snaps. 3 Connect the brake master cylinder fluid level warning switch electrical connector. 4 Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. NOTE: Whenever replacing the brake master cylinder reservoir, replace the grommets. 2. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6499 Brake Master Cylinder: Service and Repair Master Cylinder, Brakes 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. 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. - 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 replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. - Use High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. 3. Slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 4. Remove the short brake tubes. 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 IS MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system - 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 replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6500 1. Disconnect the brake master cylinder outlet tubes. NOTE: When the brake master cylinder has been replaced or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. 2. Install short brake tubes with ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes without air bubbles. 4. Remove the short brake tubes and install the brake outlet tubes. 5. Bleed each brake tube at the brake master cylinder as follows: 1 Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2 Loosen the rearmost brake tube fittings until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. 6. While the assistant maintains pressure on the brake pedal, tighten the brake tubes. Disassembly and Assembly DISASSEMBLY WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. 1. Remove the brake master cylinder. 2. Clean the outside of the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6501 3. Remove the brake master cylinder filler cap and drain the remaining brake fluid. Do not reuse the drained fluid. 4. On speed control equipped vehicles, remove the brake pressure switch. 5. Remove the brake master cylinder fluid control valve. 6. Remove the primary piston assembly. 1 Depress the primary piston, and remove the snap ring. 2 Remove and discard the primary piston assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6502 7. Remove the secondary piston assembly. 1 Plug the rear outlet port and, if necessary, plug the brake pressure switch port. 2 Apply compressed air into the front outlet port, and carefully remove the secondary piston assembly and discard. 8. Use isopropyl alcohol to clean and inspect the brake master cylinder bore for damage. NOTE: If the brake master cylinder bore is damaged, the brake master cylinder must be replaced. ASSEMBLY WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. 1. Lubricate the new piston assembly seals.Use clean High-Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Do not use oil as it will destroy the seals. 2. Carefully install the secondary piston assembly Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6503 3. Carefully install the primary piston assembly. 4. Install the snap ring. 1 Depress the primary piston. 2 Install the snap ring. 5. Install the brake master cylinder fluid control valve. 6. On speed control equipped vehicles, install the brake pressure switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6504 7. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A, and install the brake master cylinder filler cap. 8. Bleed the brake master cylinder. 9. Install the brake master cylinder. Removal and Installation REMOVAL WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. 1. Disconnect the battery ground cable. 2. Disconnect the brake fluid level warning switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6505 3. On speed control equipped vehicles, disconnect the brake pressure switch electrical connector. 4. Disconnect the two brake lines. and plug the lines and the brake master cylinder ports. NOTE: Use two wrenches on the tube nut at the control valve so as not to loosen the valve. 5. Remove the brake master cylinder 1 Remove the two brake master cylinder nuts. 2 Remove the brake master cylinder. INSTALLATION 1. Follow the removal procedure in reverse order. - Bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6506 NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km ( 10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Page 6507 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications Parking Brake Cable: Specifications TORQUE SPECIFICATIONS Cable And Conduit Clip Bolt .................................................................................................................................................. 15-20 Nm (11-14.7 ft. lbs.) Cable Retainer Clip Screw ........................................................................................................................................................... 11-15 Nm (8-11 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable and Conduit Parking Brake Cable: Service and Repair Front Cable and Conduit REMOVAL 1. Remove the parking brake control. 2. Disconnect the front parking brake cable and conduit from the RH parking brake rear cable and conduit. 3. Remove the front parking brake cable and conduit. 1 Pry the rubber seal from the front floor pan 2 Compress the retainer and release the front parking brake cable and conduit from the bracket. 3 Remove the front parking brake cable and conduit. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable and Conduit > Page 6514 Parking Brake Cable: Service and Repair Rear Cable and Conduit LH Rear Cable and Conduit REMOVAL 1. Relieve the tension on the parking brake system. 1 Pull the front parking brake cable and conduit 2 Insert a suitable retainer. NOTE: Make sure the parking brake control is fully released. 2. Raise and support the vehicle. 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. 3. Separate the RH parking brake rear cable and conduit from the LH parking brake rear cable and conduit at the parking brake cable equalizer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable and Conduit > Page 6515 4. Remove the LH parking brake rear cable and conduit from the parking brake cable bracket. 1 Compress the parking brake cable clip. 2 Remove the LH parking brake rear cable and conduit from the parking brake cable bracket. 5. Remove the screw. 6. Compress the retainer and release the parking brake rear cable and conduit from the rear disc brake caliper anchor plate. 7. Unclip the parking brake rear cable and conduit from the parking brake lever. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable and Conduit > Page 6516 1. Follow the removal procedure in reverse order. RH Rear Cable and Conduit REMOVAL 1. Relieve the tension on the parking brake system. 1 Pull the front parking brake cable and conduit. 2 Insert a suitable retainer. NOTE: Make sure the parking brake control is fully released. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable and Conduit > Page 6517 3. Disconnect the front parking brake cable and conduit from the RH parking brake rear cable and conduit. 4. Compress the parking brake cable clip. Remove the RH parking brake rear cable and conduit from the parking brake cable equalizer. 5. Remove the screw. 6. Compress the retainer and release the parking brake rear cable and conduit from the rear disc brake caliper anchor plate. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable and Conduit > Page 6518 7. Unclip the parking brake rear cable and conduit from the parking brake lever. 8. Remove the pushpin located in the crossmember and the RH parking brake rear cable and conduit. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications Parking Brake Control: Specifications TORQUE SPECIFICATIONS Parking Brake Control Cowl Panel Bolts ................................................................................................................................ 15-20 Nm (11-14.7 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6522 Parking Brake Control: Service and Repair REMOVAL 1. Relieve the tension on the parking brake system. 1 Pull the front parking brake cable and conduit. 2 Insert a suitable retainer NOTE: Make sure the parking brake control is fully released. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6523 4. Pull to release the three clips and remove the instrument panel steering column cover. 5. Remove the parking brake remote release lever screws. 6. Unhook the remote release lever from the parking brake control. 1 Unhook the cable. 2 Remove the conduit from the clip. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6524 7. Separate the parking brake control from the cowl panel. 1 Remove the bolts. 2 Disconnect the parking brake signal switch connector. 3 Separate the parking brake control from the cowl panel. 8. Disconnect the front parking brake cable and conduit from the parking brake control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6525 9. Remove the parking brake control. 1 Compress the connector; release the front parking brake cable and conduit. 2 Remove the front parking brake cable and conduit. 3 Remove the parking brake control. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications TORQUE SPECIFICATIONS Parking Brake Remote Release To Instrument Panel Bolts .............................................................................................................................................. 2.1-2.9 Nm (18.7-25.8 inch lbs.) Parking Brake Release Handle Screws ................................................................................................................................. 2.7-3.7 Nm (25-33 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair Parking Brake Shoe: Service and Repair REMOVAL 1. Relieve the tension on the parking brake system. 1 Pull the front parking brake cable and conduit. 2 Insert a suitable retainer. NOTE: Make sure the parking brake control is fully released. 2. Remove the rear disc brake rotor. 3. Remove the brake shoe retracting spring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6532 4. Remove the brake shoe adjusting screw spring 5. Remove the brake adjuster screw. 6. Remove the brake shoe hold-down spring. 7. Remove the parking brake shoe and linings. 8. Inspect the components for excessive wear or damage and replace as required. INSTALLATION 1. Install the parking brake shoe and linings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6533 2. Install the brake shoe hold-down spring. 3. Install the brake adjuster screw. 4. Install the brake shoe adjusting screw spring. 5. Install the brake shoe retracting spring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6534 6. Use the brake adjusting gauge to measure the inside diameter of the drum portion of the rear disc brake rotor. 7. Use the brake adjusting gauge to set the rear brake shoe and lining diameter. 8. Install the rear disc brake rotor. 9. Apply tension to the parking brake system. 1 Hold the front parking brake cable and conduit taut. 2 Remove the retainer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6535 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications GENERAL SPECIFICATIONS Booster Push Rod Length .......................................................................................................................................... 24.89-25.27 mm (0.980-0.995 inch) TORQUE SPECIFICATIONS Brake Booster Nuts ............................................................................................................................. ....................................... 22-28 Nm (16-21 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6540 Vacuum Brake Booster: Description and Operation The power brake booster: - is a dual diaphragm, vacuum-assisted power brake booster. - reduces brake pedal pressure and travel distance. - is located on the LH side of the bulkhead in the engine compartment, between the brake pedal and brake master cylinder. - is divided into separate chambers by the diaphragm. - will not operate if vacuum is restricted or if any of the vacuum-related power brake components fail. - is replaced as an assembly. If the power assist fails, the brake system will continue to operate with increased brake pedal effort. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Check Valve Vacuum Brake Booster: 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Check Valve > Page 6543 Vacuum Brake Booster: Testing and Inspection Operational 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, replace the 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), replace the 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Check Valve > Page 6544 Vacuum Brake Booster: Testing and Inspection Inspection 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 6545 Vacuum Brake Booster: Service and Repair REMOVAL 1. Remove the brake master cylinder. 2. Disconnect the power brake booster hose. 1 Compress the clamp. 2 Disconnect the power brake booster hose. 3. Disconnect the brake pedal to power brake booster push rod. 1 Remove the self-locking pin. 2 Remove the brake master cylinder push rod spacers. 3 Remove the stoplight switch from the brake master cylinder push rod. 4 Remove the brake master cylinder push rod bushing. 4. Remove the bulkhead sound insulator. 5. Remove the power brake booster. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 6546 1 Remove the nuts. 2 Remove the power brake booster. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation Vacuum Brake Booster Check Valve: Description and Operation The power brake booster check valve: - is located on the front of the power brake booster. - is positioned between the power brake booster and the Dower brake booster hose. - closes when the engine is turned off. - in the closed position, traps engine vacuum in the power brake booster. - retains vacuum to provide several power-assisted brake applications with the engine off. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 6554 Power Distribution Relay Box The 4 Wheel Anti-Lock Brake System Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored Electronic Brake Control Module: Customer Interest ABS - Lamp ON/DTC B1342 Stored Article No. 98-9-15 05/11/98 ^ BRAKES - 4WABS - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL VEHICLES BUILT THROUGH 2/12/98 ^ LAMP - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL - VEHICLES BUILT THROUGH 2/12/98 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B1342 may be stored in memory and/or New Generation Star (NGS) Tester may read "Invalid Code." This may be caused by the Nonvolatile Random Access Memory (NVRAM) chip inside the anti-lock brake control module not resetting at low residual voltages. ABS brake function may become inoperative, however, normal braking operation will be maintained. ACTION Replace the anti-lock brake control module. Modules with a build date of 2/19/98 or later have been revised to incorporate a new NVRAM chip. Refer to the appropriate Workshop Manual, Section 206-09, for replacement procedures. PART NUMBER PART NAME F75Z-2C065-AA Anti-lock Brake Control Module (F-150) F75Z-20065-BA Anti-lock Brake Control Module (F-250 LD) F7SZ-2C065-CA Anti-lock Brake Control Module (Expedition, Navigator) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980915A Diagnose And Replace 0.6 Hr. ABS Module - F-Series, Expedition, And Navigator DEALER CODING CONDITION BASIC PART NO. CODE 2C065 42 OASIS CODES: 206000, 301000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored Electronic Brake Control Module: All Technical Service Bulletins ABS - Lamp ON/DTC B1342 Stored Article No. 98-9-15 05/11/98 ^ BRAKES - 4WABS - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL VEHICLES BUILT THROUGH 2/12/98 ^ LAMP - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL - VEHICLES BUILT THROUGH 2/12/98 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B1342 may be stored in memory and/or New Generation Star (NGS) Tester may read "Invalid Code." This may be caused by the Nonvolatile Random Access Memory (NVRAM) chip inside the anti-lock brake control module not resetting at low residual voltages. ABS brake function may become inoperative, however, normal braking operation will be maintained. ACTION Replace the anti-lock brake control module. Modules with a build date of 2/19/98 or later have been revised to incorporate a new NVRAM chip. Refer to the appropriate Workshop Manual, Section 206-09, for replacement procedures. PART NUMBER PART NAME F75Z-2C065-AA Anti-lock Brake Control Module (F-150) F75Z-20065-BA Anti-lock Brake Control Module (F-250 LD) F7SZ-2C065-CA Anti-lock Brake Control Module (Expedition, Navigator) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980915A Diagnose And Replace 0.6 Hr. ABS Module - F-Series, Expedition, And Navigator DEALER CODING CONDITION BASIC PART NO. CODE 2C065 42 OASIS CODES: 206000, 301000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6568 Electronic Brake Control Module: Specifications TORQUE SPECIFICATIONS Control Module Screws .............................................................................................................................................................. 4-5 Nm (36-44 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6569 Electronic Brake Control Module: Locations Engine View The 4 Wheel Anti-Lock Brake System Module is located at the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6570 Electronic Brake Control Module: Diagrams 4 Wheel Anti - Lock Brake System Module ( C146) 4 Wheel Anti - Lock Brake System Module (C147) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6571 Electronic Brake Control Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the two anti-lock brake control module electrical connectors. 3. Disconnect the pump motor electrical connector from the ABS module. 4. Remove the anti-lock brake control module. 1 Remove the screws. 2 Remove the anti-lock brake control module. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6572 1. To install, reverse the removal procedure. CAUTION: Ensure that the replacement anti-lock brake control module identification sticker reads EXP. Use of any other module could result in diminished ABS performance. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6577 Brake Fluid Level Sensor/Switch: Description and Operation The brake fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) or secondary (rear) system will cause this system to activate. If the brake fluid level warning switch is inoperative, the brake master cylinder reservoir must be replaced. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations Differential Speed Sensor: Locations Body View The Differential Speed Sensor is located on the rear axle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications TORQUE SPECIFICATIONS Parking Brake Remote Release To Instrument Panel Bolts .............................................................................................................................................. 2.1-2.9 Nm (18.7-25.8 inch lbs.) Parking Brake Release Handle Screws ................................................................................................................................. 2.7-3.7 Nm (25-33 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front Anti-Lock Brake Sensor Bolt 63-80 in.lb Front ABS Sensor Wire Bracket Bolt 62-80 in.lb Rear Anti-Lock Brake Sensor Bolt 25-29 ft.lb Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring Wheel Speed Sensor: Service and Repair Toothed Ring Rear The rear sensor indicator is built into the rear differential. Refer to rear differential for disassembly and assembly procedures. Removal and Installation The front anti-lock brake sensor indicator is integral to the front wheel hub. If the indicator is bad, the wheel hub must be replaced. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 6589 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Front REMOVAL 1. Disconnect the front anti-lock brake sensor electrical connector. 2. Remove the front disc brake rotor shield. 3. Remove the (A) two front anti-lock brake sensor bolts and the (B) front anti-lock brake sensor. INSTALLATION 1. To install, reverse the removal procedure. Rear REMOVAL 1. Remove the rear anti-lock brake sensor. 1 Disconnect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 6590 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. NOTE: Remove all dirt from the mounting surface and sensor to prevent contamination of rear axle lubrication. INSTALLATION 1. Clean and inspect the rear anti-lock brake sensor. 1 Clean the axle mounting surface. 2 Inspect and clean the magnetized rear anti-lock brake sensor pole piece. 3 Inspect the rear anti-lock brake sensor O-ring for damage. Replace if necessary. 4 Lightly lubricate the rear anti-lock brake sensor O-ring with Synthetic SAE 75W-140 Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. CAUTION: Use care not to get dirt in the rear axle housing. 2. Install the rear anti-lock brake sensor. 1 Position the rear anti-lock brake sensor and install the rear anti-lock brake sensor bolt. NOTE: Do not apply force to the plastic rear anti-lock brake sensor connector. 2 Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6598 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6599 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6600 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6601 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6602 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 6603 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key and turn to the RUN position. (2) Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 6606 Ignition Switch Lock Cylinder: Service and Repair Non-Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 6607 - Thoroughly clean all drill shavings from the steering column and inspect for damage. INSTALLATION 1. To install, reverse the removal procedure, using a new ignition switch lock cylinder. - Verify ignition switch lock cylinder operation. NOTE: - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. - Use a new ignition switch lock cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Transmission View The Digital Transmission Range Sensor is located at the left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 6611 Neutral Safety Switch: Diagrams Digital Transmission Range Sensor Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications Starter Relay: Specifications Starter Motor Solenoid Relay Switch Bolts ........................................................................................................................................ 7-9 N.m (62-79 Lb-In) Starter Motor Solenoid Relay Switch Terminal Nuts ........................................................................................................................ 5-11 N.m (45-97 Lb-In) Starter Motor Solenoid Relay Switch Cable Nuts .......................................................................................................................... 5-11.2 N.m (44-99 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications > Page 6616 Starter Relay: Locations Engine View The Starter Motor Relay is located at the right rear of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications > Page 6617 Starter Relay: Description and Operation The starter motor solenoid relay switch: ^ Receives a start signal from the ignition switch as long as the digital Transmission Range (TR) sensor is in the PARK or NEUTRAL position. ^ Switches battery power to the starter motor solenoid S terminal when it receives the START signal from the ignition switch which allows the starter motor to engage and start the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications > Page 6618 Starter Relay: Service and Repair REMOVAL WARNING: WHEN PERFORMING 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 THE MAINTENANCE IS COMPLETE. 1. Disconnect the battery ground cable. 2. Remove the relay cover. 3. Disconnect the starter motor solenoid relay switch wires and cables. 1. Remove the insulator. 2. Disconnect the ignition switch signal wire. 3. Remove the nuts. 4. Remove the engine control sensor wire and the generator wire. 5. Remove the battery cables. 4. Remove the bolts and remove the starter motor solenoid relay switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications > Page 6619 1. Follow the removal procedure in reverse order. WARNING: WHEN PERFORMING 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 THE MAINTENANCE IS COMPLETE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Locations > Page 6624 Battery Cable: Service and Repair REMOVAL 1. Disconnect the battery cables. 1. Disconnect the battery ground cable. 2. Disconnect the battery to starter relay cable. 2. Remove the two nuts. 3. Remove the (A) battery ground cable body ground nut and the (B) battery ground cable body ground. 4. Remove the bolt. 5. Remove the starter motor solenoid terminal cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Locations > Page 6625 6. Disconnect the starter motor connections. 1. Remove the (A) starter motor ground cable nut and disconnect the (B) starter motor ground cable. 2. Remove the (C) solenoid cable nut and disconnect the (D) solenoid cable. 3. Remove the (F) starter motor positive cable nut and disconnect the (F) starter motor positive cable. 7. Remove the cables. INSTALLATION 1. Follow the removal procedure in reverse order. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Brush > Component Information > Specifications Alternator Brush: Specifications Generator Brush Screws .............................................................................................................................................................. 2.8-4.0 N.m (2.5-3.5 Lb-Ft) Brush and Terminal Holder Screws .................................................................................................................................................... 3-4 N.m (27-35 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Brush > Component Information > Specifications > Page 6631 Alternator Brush: Service and Repair REMOVAL 1. Remove the Generator (GEN). 2. Remove the (A) generator brush and terminal holder and the (B) voltage regulator assembly. 1. Remove the screws. 2. Remove the (A) generator brush and terminal holder and (B) voltage regulator assembly. INSTALLATION 1. Install the (A) generator brush and terminal holder and (B) voltage regulator assembly. 1. Depress the (C) brushes and insert a (D) wire to hold brushes during installation. 2. Install the (A) generator brush and terminal holder and (B) voltage regulator assembly. 3. Install the voltage regulator screws. Remove the (D) wire. 2. Install the generator. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications Voltage Regulator: Specifications Voltage Regulator Screws ............................................................................................................................................................. 2.3-3.4 N.m (20-30 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Page 6635 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Page 6636 Voltage Regulator: Service and Repair REMOVAL 1. Remove the Generator (GEN). 2. Remove the (A) generator brush and terminal holder and the (B) voltage regulator assembly. 1. Remove the screws. 2. Remove the (A) generator brush and terminal holder and (B) voltage regulator assembly. INSTALLATION 1. Install the (A) generator brush and terminal holder and (B) voltage regulator assembly. 1. Depress the (C) brushes and install a (D) wire to hold brushes during installation. 2. Install the (A) generator brush and terminal holder and (B) voltage regulator assembly. 3. Install the screws and remove the (D) wire. 2. Install the generator. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder Ignition Lock: Customer Interest Ignition Key - Hard To Remove From Ignition Cylinder Article No. 99-16-4 08/09/99 ^ IGNITION KEY - HARD TO REMOVE FROM IGNITION CYLINDER ^ IGNITION KEY - HARD TO TURN FORD: 1992-1999 ECONOLINE 1997-1999 EXPEDITION, F-150, F-25C 1999 SUPER DUTY F SERIES LINCOLN: 1998-1999 NAVIGATOR This TSB article is being republished in its entirety to add vehicles covered by this TSB. ISSUE A hard to turn ignition key, and/or a hard to remove key from ignition cylinder may occur on some vehicles. This may be caused by a misaligned shift column shaft bushing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6646 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6647 ACTION A diagnostic and repair procedure has been developed to correctly repair the concern. Refer to the following Figures 1 through 3 for details. PART NUMBER PART NAME F3TZ-7L278-A Shift Column Shaft Bushing OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-5-9 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991604A Replace Ignition Lock 0.4 Hr. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6648 Cylinder 991604B Replace Bushings 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7335 42 OASIS CODES: 112000, 602300 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder Ignition Lock: All Technical Service Bulletins Ignition Key - Hard To Remove From Ignition Cylinder Article No. 99-16-4 08/09/99 ^ IGNITION KEY - HARD TO REMOVE FROM IGNITION CYLINDER ^ IGNITION KEY - HARD TO TURN FORD: 1992-1999 ECONOLINE 1997-1999 EXPEDITION, F-150, F-25C 1999 SUPER DUTY F SERIES LINCOLN: 1998-1999 NAVIGATOR This TSB article is being republished in its entirety to add vehicles covered by this TSB. ISSUE A hard to turn ignition key, and/or a hard to remove key from ignition cylinder may occur on some vehicles. This may be caused by a misaligned shift column shaft bushing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6654 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6655 ACTION A diagnostic and repair procedure has been developed to correctly repair the concern. Refer to the following Figures 1 through 3 for details. PART NUMBER PART NAME F3TZ-7L278-A Shift Column Shaft Bushing OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-5-9 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991604A Replace Ignition Lock 0.4 Hr. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6656 Cylinder 991604B Replace Bushings 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7335 42 OASIS CODES: 112000, 602300 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6662 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6663 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6664 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6665 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6666 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 6667 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key and turn to the RUN position. (2) Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 6670 Ignition Switch Lock Cylinder: Service and Repair Non-Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 6671 - Thoroughly clean all drill shavings from the steering column and inspect for damage. INSTALLATION 1. To install, reverse the removal procedure, using a new ignition switch lock cylinder. - Verify ignition switch lock cylinder operation. NOTE: - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. - Use a new ignition switch lock cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Transmission View The Digital Transmission Range Sensor is located at the left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 6675 Neutral Safety Switch: Diagrams Digital Transmission Range Sensor Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Cable: Customer Interest Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 6684 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Cable: All Technical Service Bulletins Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 6690 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6696 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6697 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6703 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6704 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Page 6705 Starter Cable: Specifications Starter Motor Ground Cable Nut ............................................................................................................................................... 21.2-38.8 N.m (15-28 Lb-Ft) Starter Motor Positive Cable Nut .................................................................................................................................................. 6.8-9.2 N.m (60-82 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Testing and Inspection Starter Drive/Bendix: Testing and Inspection 1. Remove the starter motor. 2. Check the wear patterns on the (A) starter drive and the (B) flywheel ring gear. If the wear pattern is normal, install the starter motor. 3. If the (A) starter drive gear and the flywheel ring gear are not fully meshing or the gears are (B) milled or damaged, replace the starter motor. Replace the flywheel ring gear. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Specifications Starter Relay: Specifications Starter Motor Solenoid Relay Switch Bolts ........................................................................................................................................ 7-9 N.m (62-79 Lb-In) Starter Motor Solenoid Relay Switch Terminal Nuts ........................................................................................................................ 5-11 N.m (45-97 Lb-In) Starter Motor Solenoid Relay Switch Cable Nuts .......................................................................................................................... 5-11.2 N.m (44-99 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Specifications > Page 6713 Starter Relay: Locations Engine View The Starter Motor Relay is located at the right rear of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Specifications > Page 6714 Starter Relay: Description and Operation The starter motor solenoid relay switch: ^ Receives a start signal from the ignition switch as long as the digital Transmission Range (TR) sensor is in the PARK or NEUTRAL position. ^ Switches battery power to the starter motor solenoid S terminal when it receives the START signal from the ignition switch which allows the starter motor to engage and start the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Specifications > Page 6715 Starter Relay: Service and Repair REMOVAL WARNING: WHEN PERFORMING 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 THE MAINTENANCE IS COMPLETE. 1. Disconnect the battery ground cable. 2. Remove the relay cover. 3. Disconnect the starter motor solenoid relay switch wires and cables. 1. Remove the insulator. 2. Disconnect the ignition switch signal wire. 3. Remove the nuts. 4. Remove the engine control sensor wire and the generator wire. 5. Remove the battery cables. 4. Remove the bolts and remove the starter motor solenoid relay switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Specifications > Page 6716 1. Follow the removal procedure in reverse order. WARNING: WHEN PERFORMING 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 THE MAINTENANCE IS COMPLETE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications Starter Solenoid: Specifications Starter Solenoid Terminal Nuts ........................................................................................................................................................... 7-9 N.m (61-79 Lb-In) Solenoid Cable Nut .......................................................................................... ............................................................................. 4.5-6.3 N.m (40-56 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6729 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6730 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6731 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6732 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6733 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6734 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6735 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6736 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6742 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6743 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6744 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6745 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6746 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6747 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6748 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6749 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6755 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 Fuse: Electrical Diagrams Generator Mega Fuse (Alternator) - The 175 Amp Mega Fuse (Generator) protects the in-line fuse & generator/voltage regulator. Power Distribution PDB Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 Mega Fuse (PDB) - The 175 Amp Mega Fuse (PDB) protects the power distribution box. Power Distribution Mini Fuse Mini Fuse - The 20 Amp Mini Fuse protects the generator/voltage regulator. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 Power Distribution Fuse 1 Fuse 1 - protects the following circuits: ^ Powertrain Control Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Trailer Tow Left Turn Relay ^ Trailer Tow Right Turn Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ Radio ^ Rear Integrated Control Panel ^ Compact Disc Changer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Sub-Woofer Power ^ Premium Sound Amplifier Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 Power Distribution Fuse 1 Fuse 1 - protects the following circuits: ^ Flasher Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Instrument Cluster ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ Cigar Lighter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6770 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ Park Lamp Relay ^ Headlamp Relay ^ Autolamp Module ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 ^ Power Mirror Switch Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 ^ Speed Control Servo/Amplifier Assembly ^ Heater-A/C Control Assembly ^ Blend Door Actuator ^ Electronic Variable Orifice Module Power Distribution Fuse 6 Fuse 6 - protects the following circuits: ^ Shift Lock Actuator Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6773 ^ Generic Electronic Module ^ 4 Wheel Air Suspension Module ^ Compass Sensor ^ Steering Wheel Rotation Sensor ^ Heated Grid Relay ^ Overhead Trip Computer Module Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6774 Fuse 7 Fuse 7 - protects the following circuits: ^ Auxiliary A/C Relay ^ Console Blower Motor Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Radio ^ Main Light Switch ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Washer Pump Relay ^ Wiper Run/Park Relay ^ Wiper High/Low Relay ^ Windshield Wiper Motor ^ Rear Wiper Pump Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: ^ Data Link Connector Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Brake Pedal Position Switch ^ Brake Pressure Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6779 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: ^ Battery Saver Relay ^ Interior Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6780 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Generic Electronic Module ^ Passive Anti-Theft System Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6781 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Instrument Cluster (Without Daytime Running Lamps) ^ Daytime Running Lamps Module ^ High Beam Headlamps Power Source Power is Supplied Through Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6782 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Heated Backlight Switch ^ Left Power/Heated Signal Mirror ^ Right Power/Heated Signal Mirror Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6783 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Main Light Switch ^ Generic Electronic Module ^ Instrument Illumination Power Source Power is Supplied Through Main Light Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6784 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: ^ Instrument Cluster ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6785 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: ^ 4 Wheel Air Suspension ^ Generic Electronic Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6786 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Junction Box Fuse/Relay Panel Fuse 20 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6787 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6788 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ 4X4 Center Axle Disconnect Solenoid ^ Function Selector Switch ^ Rear Integrated Control Panel ^ Recirculation Vacuum Solenoid Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6789 ^ Auxiliary A/C Mode Actuator ^ Auxiliary A/C Control Module Power Distribution Fuse 24 Fuse 24 - protects the following circuits: ^ Function Selector Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6790 Power Distribution Fuse 25 Fuse 25 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System (4WABS) Module ^ 4WABS Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6791 Power Distribution Fuse 26 Fuse 26 - protects the following circuits: ^ Daytime Running Lamps Module ^ Right Headlamp Power Source Power is Supplied Through Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6792 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: ^ Main Light Switch ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6793 Power Distribution Fuse 28 Fuse 28 - protects the following circuits: ^ Left Headlamp Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6794 Power Distribution Fuse 29 Fuse 29 - protects the following circuits: ^ Autolamp Module ^ Instrument Cluster ^ Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6795 Power Distribution Fuse 30 Fuse 30 - protects the following circuits: ^ Radio Noise Capacitor ^ Ignition Coil ^ PCM Power Diode ^ Coil On Plugs ^ Passive Anti-Theft System Control Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6796 Power Distribution Fuse 1 Fuse 1 - protects the following circuits: ^ Trailer Tow Running Lamp Relay ^ Trailer Tow Backup Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6797 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6798 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ All Unlock Relay ^ All Lock Relay ^ Driver's Unlock Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6799 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ Air Suspension Service Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6800 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Horn Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6801 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: ^ Radio ^ Premium Sound Amplifier ^ Compact Disc Changer ^ Rear Integrated Control Panel ^ Engine Fuse Module Fuse 3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6802 ^ Engine Fuse Module Fuse 5 ^ Sub-Woofer Power Power Distribution Fuse 7 Fuse 7 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6803 ^ Main Light Switch ^ Park Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6804 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Main Light Switch ^ Headlamp Relay ^ Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6805 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6806 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: ^ Daytime Running Lamps Module ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6807 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: ^ Instrument Panel Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6808 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Console Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6809 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: ^ Rear Wiper Up Motor Relay ^ Rear Wiper Down Motor Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6810 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Auxiliary A/C Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6811 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6812 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Air Suspension Solid State Compressor Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6813 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ Engine Fuse Module Fuse 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6814 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Shift On The Fly Relay ^ Transfer Case Shift Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6815 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6816 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: ^ Fuel Pump Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6817 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: ^ Ignition Switch (B4 & B5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6818 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6819 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: ^ Ignition Switch (B1 & B3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6820 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6821 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: ^ Junction Box Fuse/Relay Panel Battery Feed Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6822 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6823 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: ^ Instrument Panel Blower Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6824 Power Distribution Fuse 24 Fuse 24 - protects the following circuits: ^ PCM Power Relay ^ Engine Fuse Module Fuse 1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6825 Power Distribution Fuse 25 Fuse 25 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6826 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6827 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Heated Grid Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6828 Power Distribution Fuse 28 Fuse 28 - protects the following circuits: ^ Trailer Electronic Brake Controller Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6829 Power Distribution Fuse 29 Fuse 29 - protects the following circuits: ^ Flip Window Relay ^ Hybrid Cooling Fan Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6830 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Engine Fuse Module Fuse Block: Locations Engine Fuse Module Engine View The Engine Fuse Module is located near the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Engine Fuse Module > Page 6835 Fuse Block: Locations Junction Box/Fuse Relay Panel Junction Box Fuse/Relay Panel (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Engine Fuse Module > Page 6836 Instrument Panel View The Junction Box/Fuse Relay Panel is located under left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6839 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6840 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6841 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6842 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6843 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6844 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6845 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6846 Fuse Block: Connector Views Junction Box/Fuse Panel (C243) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6847 Junction Box/Fuse Panel (C242) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6848 Fuse Block: Electrical Diagrams Engine Mini- Fuse Block Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6849 Junction Box Fuse/Relay Panel (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6850 Junction Box Fuse/Relay Panel (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6851 Power Distribution Box Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6852 Primary Battery Fuses Fuse 1 - Trailer Backup and Running Lamp Relays Fuse 1 - protects the following circuits: ^ Trailer Tow Running Lamp Relay ^ Trailer Tow Backup Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6853 Power Distribution Fuse 2 - Air Bag Diagnostic Monitor Fuse 2 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6854 Power Distribution Fuse 3 - All Unlock/Lock Relays, Drivers' Unlock Relay Fuse 3 - protects the following circuits: ^ All Unlock Relay ^ All Lock Relay ^ Driver's Unlock Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6855 Power Distribution Fuse 4 - Air Suspension Service Switch Fuse 4 - protects the following circuits: ^ Air Suspension Service Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6856 Power Distribution Fuse 5 - Horn Relay Fuse 5 - protects the following circuits: ^ Horn Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6857 Power Distribution Fuse 6 - Var. Sound Sys. Components, Eng. Fuse Mdl Fuses 3 & 5 Fuse 6 - protects the following circuits: ^ Radio ^ Premium Sound Amplifier ^ Compact Disc Changer ^ Rear Integrated Control Panel ^ Engine Fuse Module Fuse 3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6858 ^ Engine Fuse Module Fuse 5 ^ Sub-Woofer Power Power Distribution Fuse 7 - Main Light Switch, Park Lamp Relay Fuse 7 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6859 ^ Main Light Switch ^ Park Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6860 Power Distribution Fuse 8 - Main Light Switch, Headlamp Relay, Multi-function Sw Fuse 8 - protects the following circuits: ^ Main Light Switch ^ Headlamp Relay ^ Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6861 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6862 Power Distribution Fuse 9 - DRL Module, Fog Lamp Relay Fuse 9 - protects the following circuits: ^ Daytime Running Lamps Module ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6863 Power Distribution Fuse 10 - Instrument Panel Aux. Power Socket Fuse 10 - protects the following circuits: ^ Instrument Panel Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6864 Power Distribution Fuse 11 - Console Aux. Power Socket Fuse 11 - protects the following circuits: ^ Console Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6865 Power Distribution Fuse 12 - Rear Wiper Up And Down Motor Relays Fuse 12 - protects the following circuits: ^ Rear Wiper Up Motor Relay ^ Rear Wiper Down Motor Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6866 Power Distribution Fuse 13 - Auxiliary A/C Relay Fuse 13 - protects the following circuits: ^ Auxiliary A/C Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6867 Power Distribution Fuse 14 - 4 Wheel Anti-Lock Brake System Module Fuse 14 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6868 Power Distribution Fuse 15 - Air Suspension Solid State Compressor Relay Fuse 15 - protects the following circuits: ^ Air Suspension Solid State Compressor Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6869 Power Distribution Fuse 16 - Trailer Tow Bttry Charge Relay, Eng Fuse Module Fuse2 Fuse 16 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ Engine Fuse Module Fuse 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6870 Power Distribution Fuse 17 - Shift-On-The-Fly Relay, Tranfer Case Shift Relay Fuse 17 - protects the following circuits: ^ Shift On The Fly Relay ^ Transfer Case Shift Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6871 Power Distribution Fuse 18 - Power Seat Control Switch Fuse 18 - protects the following circuits: ^ Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6872 Power Distribution Fuse 19 - Fuel Pump Relay Fuse 19 - protects the following circuits: ^ Fuel Pump Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6873 Power Distribution Fuse 20 - Ignition Switch Fuse 20 - protects the following circuits: ^ Ignition Switch (B4 & B5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6874 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6875 Power Distribution Fuse 21 - Ignition Switch Fuse 21 - protects the following circuits: ^ Ignition Switch (B1 & B3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6876 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6877 Power Distribution Fuse 22 - Junction Box Fuse/Relay Panel Battery Feed Fuse 22 - protects the following circuits: ^ Junction Box Fuse/Relay Panel Battery Feed Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6878 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6879 Power Distribution Fuse 23 - Instrument Panel Blower Relay Fuse 23 - protects the following circuits: ^ Instrument Panel Blower Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6880 Power Distribution Fuse 24 - PCM Power Relay, Engine Fuse Module Fuse 1 Fuse 24 - protects the following circuits: ^ PCM Power Relay ^ Engine Fuse Module Fuse 1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6881 Power Distribution Fuse 25 - Junction Box Fuse/Relay Panel, Accessory Delay Relay Fuse 25 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6882 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6883 Power Distribution Fuse 27 - Junction Box Fuse/Relay Panel, Heated Grid Relay Fuse 27 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Heated Grid Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6884 Power Distribution Fuse 28 - Trailer Electronic Brake Controller Fuse 28 - protects the following circuits: ^ Trailer Electronic Brake Controller Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6885 Power Distribution Fuse 29 - Flip Window Relay, Hybrid Cooling Fan Relay Fuse 29 - protects the following circuits: ^ Flip Window Relay ^ Hybrid Cooling Fan Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6886 Power Distribution Fuse 1 - Flasher Relay Fuse 1 - protects the following circuits: ^ Flasher Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6887 Power Distribution Fuse 2 - Instrument Cluster, OH Trip Computer Fuse 2 - protects the following circuits: ^ Instrument Cluster ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6888 Power Distribution Fuse 3 - Cigar Lighter Fuse 3 - protects the following circuits: ^ Cigar Lighter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6889 Power Distribution Fuse 4 - Park & Hdlp Relays, Autolamp & RAP Mdl, Pwr Mirror Sw. Fuse 4 - protects the following circuits: ^ Park Lamp Relay ^ Headlamp Relay ^ Autolamp Module ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6890 ^ Power Mirror Switch Power Distribution Fuse 5 - TRS, DRL Mdl, Spd Ctrl Servo/Amp Assy, HVAC Ctrl Assy Fuse 5 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6891 ^ Speed Control Servo/Amplifier Assembly ^ Heater-A/C Control Assembly ^ Blend Door Actuator ^ Electronic Variable Orifice Module Power Distribution Fuse 6 - Shift Lock, GEM, Air Susp. Mdl, OH Trip Cmptr, Compass Fuse 6 - protects the following circuits: ^ Shift Lock Actuator Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6892 ^ Generic Electronic Module ^ 4 Wheel Air Suspension Module ^ Compass Sensor ^ Steering Wheel Rotation Sensor ^ Heated Grid Relay ^ Overhead Trip Computer Module Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6893 Fuse 7 - Aux. A/C Relay, Blower Motor Fuse 7 - protects the following circuits: ^ Auxiliary A/C Relay ^ Console Blower Motor Power Distribution Fuse 8 - Radio, Main Light Switch, RAP Module Fuse 8 - protects the following circuits: ^ Radio ^ Main Light Switch ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6894 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6895 Power Distribution Fuse 11 - Washer Pump, Wiper Run/Park Hi/Lo Relays, Wiper Motor Fuse 11 - protects the following circuits: ^ Washer Pump Relay ^ Wiper Run/Park Relay ^ Wiper High/Low Relay ^ Windshield Wiper Motor ^ Rear Wiper Pump Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6896 Power Distribution Fuse 12 - Data Link Connector Fuse 12 - protects the following circuits: ^ Data Link Connector Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6897 Power Distribution Fuse 13 - Brake Pedal Position and Brake Pressure Switches Fuse 13 - protects the following circuits: ^ Brake Pedal Position Switch ^ Brake Pressure Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6898 Power Distribution Fuse 14 - Battery Saver and Interior Lamp Relays Fuse 14 - protects the following circuits: ^ Battery Saver Relay ^ Interior Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6899 Power Distribution Fuse 15 - GEM and RAP Modules Fuse 15 - protects the following circuits: ^ Generic Electronic Module ^ Passive Anti-Theft System Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6900 Power Distribution Fuse 16 - Inst. Cluster, DRL Module, High Beam Headlamps Fuse 16 - protects the following circuits: ^ Instrument Cluster (Without Daytime Running Lamps) ^ Daytime Running Lamps Module ^ High Beam Headlamps Power Source Power is Supplied Through Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6901 Power Distribution Fuse 17 - Htd Backlight Sw, Left & Right Pwr/Htd Signal Mirrors Fuse 17 - protects the following circuits: ^ Heated Backlight Switch ^ Left Power/Heated Signal Mirror ^ Right Power/Heated Signal Mirror Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6902 Power Distribution Fuse 18 - Main Light Sw, GEM, Instr. Illumination Fuse 18 - protects the following circuits: ^ Main Light Switch ^ Generic Electronic Module ^ Instrument Illumination Power Source Power is Supplied Through Main Light Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6903 Power Distribution Fuse 19 - Instrument Cluster, Air Bag Diagnostic Monitor Fuse 19 - protects the following circuits: ^ Instrument Cluster ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6904 Power Distribution Fuse 20 - 4 Wheel Air Suspension, GEM Fuse 20 - protects the following circuits: ^ 4 Wheel Air Suspension ^ Generic Electronic Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6905 Power Distribution Fuse 21 - Digital Trans. Range Snsr, JB Fuse/Relay Pnl Fuse 20 Fuse 21 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Junction Box Fuse/Relay Panel Fuse 20 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6906 Power Distribution Fuse 22 - Air Bag Diagnostic Monitor Fuse 22 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6907 Power Distribution Fuse 23 - Tow Btty Chg Relay, 4X4 Ctr Axle Disc, Func Selector Fuse 23 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ 4X4 Center Axle Disconnect Solenoid ^ Function Selector Switch ^ Rear Integrated Control Panel ^ Recirculation Vacuum Solenoid Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6908 ^ Auxiliary A/C Mode Actuator ^ Auxiliary A/C Control Module Power Distribution Fuse 24 - Function Selector Switch Fuse 24 - protects the following circuits: ^ Function Selector Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6909 Power Distribution Fuse 25 - 4WABS Module and 4WABS Relay Fuse 25 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System (4WABS) Module ^ 4WABS Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6910 Power Distribution Fuse 26 - DRL Module and Right Headlamp Fuse 26 - protects the following circuits: ^ Daytime Running Lamps Module ^ Right Headlamp Power Source Power is Supplied Through Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6911 Power Distribution Fuse 27 - Main Light Switch and Fog Lamp Relay Fuse 27 - protects the following circuits: ^ Main Light Switch ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6912 Power Distribution Fuse 28 - Left Headlamp Fuse 28 - protects the following circuits: ^ Left Headlamp Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6913 Power Distribution Fuse 29 - Autolamp Module, Instrument Cluster, Trans Ctrl Sw Fuse 29 - protects the following circuits: ^ Autolamp Module ^ Instrument Cluster ^ Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6914 Power Distribution Fuse 30 - Radio Noise Cap., Ignition Coil, PCM Pwr Diode... Fuse 30 - protects the following circuits: ^ Radio Noise Capacitor ^ Ignition Coil ^ PCM Power Diode ^ Coil On Plugs ^ Passive Anti-Theft System Control Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6915 Power Distribution Fuse 1 - Powertrain Control Module Fuse 1 - protects the following circuits: ^ Powertrain Control Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6916 Power Distribution Fuse 2 - Trailer Tow Left and Right Turn Relays Fuse 2 - protects the following circuits: ^ Trailer Tow Left Turn Relay ^ Trailer Tow Right Turn Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6917 Power Distribution Fuse 3 - Radio, Rear Integrated Control Panel, CD Changer Fuse 3 - protects the following circuits: ^ Radio ^ Rear Integrated Control Panel ^ Compact Disc Changer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6918 Power Distribution Fuse 5 - Subwoofer Power, Premium Sound Amplifier Fuse 5 - protects the following circuits: ^ Sub-Woofer Power ^ Premium Sound Amplifier Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6919 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 In-Line Connector Faces - C119 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6924 In-Line Connector Faces - C120 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6925 In-Line Connector Faces - C148 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6926 In-Line Connector Faces - C149 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6927 Multiple Junction Connector: Diagrams In-Line Connector Faces - C119 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6928 In-Line Connector Faces - C120 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6929 In-Line Connector Faces - C148 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6930 In-Line Connector Faces - C149 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6931 In-Line Connector Faces - C158 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6932 In-Line Connector Faces - C159 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6933 In-Line Connector Faces - C160 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6934 In-Line Connector Faces - C172 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6935 In-Line Connector Faces - C201 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6936 In-Line Connector Faces - C201 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6937 In-Line Connector Faces - C203 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6938 In-Line Connector Faces - C206 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6939 In-Line Connector Faces - C210 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6940 In-Line Connector Faces - C232 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6941 In-Line Connector Faces - C247 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6942 In-Line Connector Faces - C248 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6943 In-Line Connector Faces - C253 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6944 In-Line Connector Faces - C269 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6945 In-Line Connector Faces - C271 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6946 In-Line Connector Faces - C300 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6947 In-Line Connector Faces - C429 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6948 In-Line Connector Faces - C431 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6949 In-Line Connector Faces - C432 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6950 In-Line Connector Faces - C455 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6951 In-Line Connector Faces - C917 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6952 In-Line Connector Faces - C921 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6953 In-Line Connector Faces - C921 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6954 In-Line Connector Faces - C921 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6955 In-Line Connector Faces - C922 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6956 In-Line Connector Faces - C941 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay Power Distribution Relay: Locations Trailer Tow Backup Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6961 Power Distribution Relay Box The Trailer Tow Backup Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6962 Power Distribution Relay: Locations Trailer Tow Battery Charge Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6963 Power Distribution Relay Box The Trailer Tow Battery Charge Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6964 Power Distribution Relay: Locations Trailer Tow Left Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6965 Power Distribution Relay Box The Trailer Tow Left Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6966 Power Distribution Relay: Locations Trailer Tow Right Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6967 Power Distribution Relay Box The Trailer Tow Right Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6968 Power Distribution Relay: Locations Trailer Tow Running Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6969 Power Distribution Relay Box The Trailer Tow Running Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay Power Distribution Relay: Locations Trailer Tow Backup Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6975 Power Distribution Relay Box The Trailer Tow Backup Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6976 Power Distribution Relay: Locations Trailer Tow Battery Charge Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6977 Power Distribution Relay Box The Trailer Tow Battery Charge Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6978 Power Distribution Relay: Locations Trailer Tow Left Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6979 Power Distribution Relay Box The Trailer Tow Left Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6980 Power Distribution Relay: Locations Trailer Tow Right Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6981 Power Distribution Relay Box The Trailer Tow Right Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6982 Power Distribution Relay: Locations Trailer Tow Running Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 6983 Power Distribution Relay Box The Trailer Tow Running Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block Relay Box: Locations Blower/Flasher Relay Block Instrument Panel View The Blower/Flasher Relay Block is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 6988 Relay Box: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 6989 Relay Box: Locations Regular Production Option Relay Block Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Blower/Flasher Relay Block Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 6992 Lock Relays Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 6993 Power Distribution Relay Box Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 6994 RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block Relay Box: Locations Blower/Flasher Relay Block Instrument Panel View The Blower/Flasher Relay Block is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 6999 Relay Box: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 7000 Relay Box: Locations Regular Production Option Relay Block Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Blower/Flasher Relay Block Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7003 Lock Relays Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7004 Power Distribution Relay Box Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7005 RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7015 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7016 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7017 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7018 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7019 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7020 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7021 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7022 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7028 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7029 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7030 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7031 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7032 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7033 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7034 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7035 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7040 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7041 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7042 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7043 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7044 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7045 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7046 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7047 Fuse: Electrical Diagrams Generator Mega Fuse (Alternator) - The 175 Amp Mega Fuse (Generator) protects the in-line fuse & generator/voltage regulator. Power Distribution PDB Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7048 Mega Fuse (PDB) - The 175 Amp Mega Fuse (PDB) protects the power distribution box. Power Distribution Mini Fuse Mini Fuse - The 20 Amp Mini Fuse protects the generator/voltage regulator. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7049 Power Distribution Fuse 1 Fuse 1 - protects the following circuits: ^ Powertrain Control Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7050 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Trailer Tow Left Turn Relay ^ Trailer Tow Right Turn Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7051 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ Radio ^ Rear Integrated Control Panel ^ Compact Disc Changer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7052 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Sub-Woofer Power ^ Premium Sound Amplifier Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7053 Power Distribution Fuse 1 Fuse 1 - protects the following circuits: ^ Flasher Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7054 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Instrument Cluster ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7055 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ Cigar Lighter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7056 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ Park Lamp Relay ^ Headlamp Relay ^ Autolamp Module ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7057 ^ Power Mirror Switch Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7058 ^ Speed Control Servo/Amplifier Assembly ^ Heater-A/C Control Assembly ^ Blend Door Actuator ^ Electronic Variable Orifice Module Power Distribution Fuse 6 Fuse 6 - protects the following circuits: ^ Shift Lock Actuator Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7059 ^ Generic Electronic Module ^ 4 Wheel Air Suspension Module ^ Compass Sensor ^ Steering Wheel Rotation Sensor ^ Heated Grid Relay ^ Overhead Trip Computer Module Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7060 Fuse 7 Fuse 7 - protects the following circuits: ^ Auxiliary A/C Relay ^ Console Blower Motor Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Radio ^ Main Light Switch ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7061 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7062 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Washer Pump Relay ^ Wiper Run/Park Relay ^ Wiper High/Low Relay ^ Windshield Wiper Motor ^ Rear Wiper Pump Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7063 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: ^ Data Link Connector Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7064 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Brake Pedal Position Switch ^ Brake Pressure Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7065 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: ^ Battery Saver Relay ^ Interior Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7066 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Generic Electronic Module ^ Passive Anti-Theft System Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7067 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Instrument Cluster (Without Daytime Running Lamps) ^ Daytime Running Lamps Module ^ High Beam Headlamps Power Source Power is Supplied Through Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7068 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Heated Backlight Switch ^ Left Power/Heated Signal Mirror ^ Right Power/Heated Signal Mirror Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7069 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Main Light Switch ^ Generic Electronic Module ^ Instrument Illumination Power Source Power is Supplied Through Main Light Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7070 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: ^ Instrument Cluster ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7071 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: ^ 4 Wheel Air Suspension ^ Generic Electronic Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7072 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Junction Box Fuse/Relay Panel Fuse 20 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7073 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7074 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ 4X4 Center Axle Disconnect Solenoid ^ Function Selector Switch ^ Rear Integrated Control Panel ^ Recirculation Vacuum Solenoid Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7075 ^ Auxiliary A/C Mode Actuator ^ Auxiliary A/C Control Module Power Distribution Fuse 24 Fuse 24 - protects the following circuits: ^ Function Selector Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7076 Power Distribution Fuse 25 Fuse 25 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System (4WABS) Module ^ 4WABS Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7077 Power Distribution Fuse 26 Fuse 26 - protects the following circuits: ^ Daytime Running Lamps Module ^ Right Headlamp Power Source Power is Supplied Through Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7078 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: ^ Main Light Switch ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7079 Power Distribution Fuse 28 Fuse 28 - protects the following circuits: ^ Left Headlamp Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7080 Power Distribution Fuse 29 Fuse 29 - protects the following circuits: ^ Autolamp Module ^ Instrument Cluster ^ Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7081 Power Distribution Fuse 30 Fuse 30 - protects the following circuits: ^ Radio Noise Capacitor ^ Ignition Coil ^ PCM Power Diode ^ Coil On Plugs ^ Passive Anti-Theft System Control Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7082 Power Distribution Fuse 1 Fuse 1 - protects the following circuits: ^ Trailer Tow Running Lamp Relay ^ Trailer Tow Backup Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7083 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7084 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ All Unlock Relay ^ All Lock Relay ^ Driver's Unlock Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7085 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ Air Suspension Service Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7086 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Horn Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7087 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: ^ Radio ^ Premium Sound Amplifier ^ Compact Disc Changer ^ Rear Integrated Control Panel ^ Engine Fuse Module Fuse 3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7088 ^ Engine Fuse Module Fuse 5 ^ Sub-Woofer Power Power Distribution Fuse 7 Fuse 7 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7089 ^ Main Light Switch ^ Park Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7090 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Main Light Switch ^ Headlamp Relay ^ Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7091 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7092 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: ^ Daytime Running Lamps Module ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7093 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: ^ Instrument Panel Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7094 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Console Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7095 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: ^ Rear Wiper Up Motor Relay ^ Rear Wiper Down Motor Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7096 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Auxiliary A/C Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7097 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7098 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Air Suspension Solid State Compressor Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7099 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ Engine Fuse Module Fuse 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7100 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Shift On The Fly Relay ^ Transfer Case Shift Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7101 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7102 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: ^ Fuel Pump Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7103 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: ^ Ignition Switch (B4 & B5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7104 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7105 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: ^ Ignition Switch (B1 & B3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7106 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7107 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: ^ Junction Box Fuse/Relay Panel Battery Feed Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7108 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7109 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: ^ Instrument Panel Blower Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7110 Power Distribution Fuse 24 Fuse 24 - protects the following circuits: ^ PCM Power Relay ^ Engine Fuse Module Fuse 1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7111 Power Distribution Fuse 25 Fuse 25 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7112 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7113 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Heated Grid Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7114 Power Distribution Fuse 28 Fuse 28 - protects the following circuits: ^ Trailer Electronic Brake Controller Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7115 Power Distribution Fuse 29 Fuse 29 - protects the following circuits: ^ Flip Window Relay ^ Hybrid Cooling Fan Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7116 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Engine Fuse Module Fuse Block: Locations Engine Fuse Module Engine View The Engine Fuse Module is located near the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Engine Fuse Module > Page 7121 Fuse Block: Locations Junction Box/Fuse Relay Panel Junction Box Fuse/Relay Panel (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Engine Fuse Module > Page 7122 Instrument Panel View The Junction Box/Fuse Relay Panel is located under left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7125 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7126 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7127 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7128 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7129 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7130 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7131 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7132 Fuse Block: Connector Views Junction Box/Fuse Panel (C243) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7133 Junction Box/Fuse Panel (C242) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7134 Fuse Block: Electrical Diagrams Engine Mini- Fuse Block Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7135 Junction Box Fuse/Relay Panel (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7136 Junction Box Fuse/Relay Panel (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7137 Power Distribution Box Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7138 Primary Battery Fuses Fuse 1 - Trailer Backup and Running Lamp Relays Fuse 1 - protects the following circuits: ^ Trailer Tow Running Lamp Relay ^ Trailer Tow Backup Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7139 Power Distribution Fuse 2 - Air Bag Diagnostic Monitor Fuse 2 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7140 Power Distribution Fuse 3 - All Unlock/Lock Relays, Drivers' Unlock Relay Fuse 3 - protects the following circuits: ^ All Unlock Relay ^ All Lock Relay ^ Driver's Unlock Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7141 Power Distribution Fuse 4 - Air Suspension Service Switch Fuse 4 - protects the following circuits: ^ Air Suspension Service Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7142 Power Distribution Fuse 5 - Horn Relay Fuse 5 - protects the following circuits: ^ Horn Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7143 Power Distribution Fuse 6 - Var. Sound Sys. Components, Eng. Fuse Mdl Fuses 3 & 5 Fuse 6 - protects the following circuits: ^ Radio ^ Premium Sound Amplifier ^ Compact Disc Changer ^ Rear Integrated Control Panel ^ Engine Fuse Module Fuse 3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7144 ^ Engine Fuse Module Fuse 5 ^ Sub-Woofer Power Power Distribution Fuse 7 - Main Light Switch, Park Lamp Relay Fuse 7 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7145 ^ Main Light Switch ^ Park Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7146 Power Distribution Fuse 8 - Main Light Switch, Headlamp Relay, Multi-function Sw Fuse 8 - protects the following circuits: ^ Main Light Switch ^ Headlamp Relay ^ Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7147 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7148 Power Distribution Fuse 9 - DRL Module, Fog Lamp Relay Fuse 9 - protects the following circuits: ^ Daytime Running Lamps Module ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7149 Power Distribution Fuse 10 - Instrument Panel Aux. Power Socket Fuse 10 - protects the following circuits: ^ Instrument Panel Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7150 Power Distribution Fuse 11 - Console Aux. Power Socket Fuse 11 - protects the following circuits: ^ Console Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7151 Power Distribution Fuse 12 - Rear Wiper Up And Down Motor Relays Fuse 12 - protects the following circuits: ^ Rear Wiper Up Motor Relay ^ Rear Wiper Down Motor Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7152 Power Distribution Fuse 13 - Auxiliary A/C Relay Fuse 13 - protects the following circuits: ^ Auxiliary A/C Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7153 Power Distribution Fuse 14 - 4 Wheel Anti-Lock Brake System Module Fuse 14 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7154 Power Distribution Fuse 15 - Air Suspension Solid State Compressor Relay Fuse 15 - protects the following circuits: ^ Air Suspension Solid State Compressor Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7155 Power Distribution Fuse 16 - Trailer Tow Bttry Charge Relay, Eng Fuse Module Fuse2 Fuse 16 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ Engine Fuse Module Fuse 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7156 Power Distribution Fuse 17 - Shift-On-The-Fly Relay, Tranfer Case Shift Relay Fuse 17 - protects the following circuits: ^ Shift On The Fly Relay ^ Transfer Case Shift Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7157 Power Distribution Fuse 18 - Power Seat Control Switch Fuse 18 - protects the following circuits: ^ Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7158 Power Distribution Fuse 19 - Fuel Pump Relay Fuse 19 - protects the following circuits: ^ Fuel Pump Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7159 Power Distribution Fuse 20 - Ignition Switch Fuse 20 - protects the following circuits: ^ Ignition Switch (B4 & B5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7160 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7161 Power Distribution Fuse 21 - Ignition Switch Fuse 21 - protects the following circuits: ^ Ignition Switch (B1 & B3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7162 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7163 Power Distribution Fuse 22 - Junction Box Fuse/Relay Panel Battery Feed Fuse 22 - protects the following circuits: ^ Junction Box Fuse/Relay Panel Battery Feed Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7164 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7165 Power Distribution Fuse 23 - Instrument Panel Blower Relay Fuse 23 - protects the following circuits: ^ Instrument Panel Blower Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7166 Power Distribution Fuse 24 - PCM Power Relay, Engine Fuse Module Fuse 1 Fuse 24 - protects the following circuits: ^ PCM Power Relay ^ Engine Fuse Module Fuse 1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7167 Power Distribution Fuse 25 - Junction Box Fuse/Relay Panel, Accessory Delay Relay Fuse 25 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7168 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7169 Power Distribution Fuse 27 - Junction Box Fuse/Relay Panel, Heated Grid Relay Fuse 27 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Heated Grid Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7170 Power Distribution Fuse 28 - Trailer Electronic Brake Controller Fuse 28 - protects the following circuits: ^ Trailer Electronic Brake Controller Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7171 Power Distribution Fuse 29 - Flip Window Relay, Hybrid Cooling Fan Relay Fuse 29 - protects the following circuits: ^ Flip Window Relay ^ Hybrid Cooling Fan Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7172 Power Distribution Fuse 1 - Flasher Relay Fuse 1 - protects the following circuits: ^ Flasher Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7173 Power Distribution Fuse 2 - Instrument Cluster, OH Trip Computer Fuse 2 - protects the following circuits: ^ Instrument Cluster ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7174 Power Distribution Fuse 3 - Cigar Lighter Fuse 3 - protects the following circuits: ^ Cigar Lighter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7175 Power Distribution Fuse 4 - Park & Hdlp Relays, Autolamp & RAP Mdl, Pwr Mirror Sw. Fuse 4 - protects the following circuits: ^ Park Lamp Relay ^ Headlamp Relay ^ Autolamp Module ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7176 ^ Power Mirror Switch Power Distribution Fuse 5 - TRS, DRL Mdl, Spd Ctrl Servo/Amp Assy, HVAC Ctrl Assy Fuse 5 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7177 ^ Speed Control Servo/Amplifier Assembly ^ Heater-A/C Control Assembly ^ Blend Door Actuator ^ Electronic Variable Orifice Module Power Distribution Fuse 6 - Shift Lock, GEM, Air Susp. Mdl, OH Trip Cmptr, Compass Fuse 6 - protects the following circuits: ^ Shift Lock Actuator Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7178 ^ Generic Electronic Module ^ 4 Wheel Air Suspension Module ^ Compass Sensor ^ Steering Wheel Rotation Sensor ^ Heated Grid Relay ^ Overhead Trip Computer Module Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7179 Fuse 7 - Aux. A/C Relay, Blower Motor Fuse 7 - protects the following circuits: ^ Auxiliary A/C Relay ^ Console Blower Motor Power Distribution Fuse 8 - Radio, Main Light Switch, RAP Module Fuse 8 - protects the following circuits: ^ Radio ^ Main Light Switch ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7180 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7181 Power Distribution Fuse 11 - Washer Pump, Wiper Run/Park Hi/Lo Relays, Wiper Motor Fuse 11 - protects the following circuits: ^ Washer Pump Relay ^ Wiper Run/Park Relay ^ Wiper High/Low Relay ^ Windshield Wiper Motor ^ Rear Wiper Pump Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7182 Power Distribution Fuse 12 - Data Link Connector Fuse 12 - protects the following circuits: ^ Data Link Connector Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7183 Power Distribution Fuse 13 - Brake Pedal Position and Brake Pressure Switches Fuse 13 - protects the following circuits: ^ Brake Pedal Position Switch ^ Brake Pressure Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7184 Power Distribution Fuse 14 - Battery Saver and Interior Lamp Relays Fuse 14 - protects the following circuits: ^ Battery Saver Relay ^ Interior Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7185 Power Distribution Fuse 15 - GEM and RAP Modules Fuse 15 - protects the following circuits: ^ Generic Electronic Module ^ Passive Anti-Theft System Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7186 Power Distribution Fuse 16 - Inst. Cluster, DRL Module, High Beam Headlamps Fuse 16 - protects the following circuits: ^ Instrument Cluster (Without Daytime Running Lamps) ^ Daytime Running Lamps Module ^ High Beam Headlamps Power Source Power is Supplied Through Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7187 Power Distribution Fuse 17 - Htd Backlight Sw, Left & Right Pwr/Htd Signal Mirrors Fuse 17 - protects the following circuits: ^ Heated Backlight Switch ^ Left Power/Heated Signal Mirror ^ Right Power/Heated Signal Mirror Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7188 Power Distribution Fuse 18 - Main Light Sw, GEM, Instr. Illumination Fuse 18 - protects the following circuits: ^ Main Light Switch ^ Generic Electronic Module ^ Instrument Illumination Power Source Power is Supplied Through Main Light Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7189 Power Distribution Fuse 19 - Instrument Cluster, Air Bag Diagnostic Monitor Fuse 19 - protects the following circuits: ^ Instrument Cluster ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7190 Power Distribution Fuse 20 - 4 Wheel Air Suspension, GEM Fuse 20 - protects the following circuits: ^ 4 Wheel Air Suspension ^ Generic Electronic Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7191 Power Distribution Fuse 21 - Digital Trans. Range Snsr, JB Fuse/Relay Pnl Fuse 20 Fuse 21 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Junction Box Fuse/Relay Panel Fuse 20 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7192 Power Distribution Fuse 22 - Air Bag Diagnostic Monitor Fuse 22 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7193 Power Distribution Fuse 23 - Tow Btty Chg Relay, 4X4 Ctr Axle Disc, Func Selector Fuse 23 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ 4X4 Center Axle Disconnect Solenoid ^ Function Selector Switch ^ Rear Integrated Control Panel ^ Recirculation Vacuum Solenoid Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7194 ^ Auxiliary A/C Mode Actuator ^ Auxiliary A/C Control Module Power Distribution Fuse 24 - Function Selector Switch Fuse 24 - protects the following circuits: ^ Function Selector Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7195 Power Distribution Fuse 25 - 4WABS Module and 4WABS Relay Fuse 25 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System (4WABS) Module ^ 4WABS Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7196 Power Distribution Fuse 26 - DRL Module and Right Headlamp Fuse 26 - protects the following circuits: ^ Daytime Running Lamps Module ^ Right Headlamp Power Source Power is Supplied Through Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7197 Power Distribution Fuse 27 - Main Light Switch and Fog Lamp Relay Fuse 27 - protects the following circuits: ^ Main Light Switch ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7198 Power Distribution Fuse 28 - Left Headlamp Fuse 28 - protects the following circuits: ^ Left Headlamp Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7199 Power Distribution Fuse 29 - Autolamp Module, Instrument Cluster, Trans Ctrl Sw Fuse 29 - protects the following circuits: ^ Autolamp Module ^ Instrument Cluster ^ Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7200 Power Distribution Fuse 30 - Radio Noise Cap., Ignition Coil, PCM Pwr Diode... Fuse 30 - protects the following circuits: ^ Radio Noise Capacitor ^ Ignition Coil ^ PCM Power Diode ^ Coil On Plugs ^ Passive Anti-Theft System Control Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7201 Power Distribution Fuse 1 - Powertrain Control Module Fuse 1 - protects the following circuits: ^ Powertrain Control Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7202 Power Distribution Fuse 2 - Trailer Tow Left and Right Turn Relays Fuse 2 - protects the following circuits: ^ Trailer Tow Left Turn Relay ^ Trailer Tow Right Turn Relay Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7203 Power Distribution Fuse 3 - Radio, Rear Integrated Control Panel, CD Changer Fuse 3 - protects the following circuits: ^ Radio ^ Rear Integrated Control Panel ^ Compact Disc Changer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7204 Power Distribution Fuse 5 - Subwoofer Power, Premium Sound Amplifier Fuse 5 - protects the following circuits: ^ Sub-Woofer Power ^ Premium Sound Amplifier Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7205 Power Distribution Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 In-Line Connector Faces - C119 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7210 In-Line Connector Faces - C120 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7211 In-Line Connector Faces - C148 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7212 In-Line Connector Faces - C149 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7213 Multiple Junction Connector: Diagrams In-Line Connector Faces - C119 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7214 In-Line Connector Faces - C120 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7215 In-Line Connector Faces - C148 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7216 In-Line Connector Faces - C149 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7217 In-Line Connector Faces - C158 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7218 In-Line Connector Faces - C159 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7219 In-Line Connector Faces - C160 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7220 In-Line Connector Faces - C172 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7221 In-Line Connector Faces - C201 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7222 In-Line Connector Faces - C201 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7223 In-Line Connector Faces - C203 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7224 In-Line Connector Faces - C206 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7225 In-Line Connector Faces - C210 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7226 In-Line Connector Faces - C232 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7227 In-Line Connector Faces - C247 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7228 In-Line Connector Faces - C248 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7229 In-Line Connector Faces - C253 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7230 In-Line Connector Faces - C269 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7231 In-Line Connector Faces - C271 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7232 In-Line Connector Faces - C300 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7233 In-Line Connector Faces - C429 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7234 In-Line Connector Faces - C431 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7235 In-Line Connector Faces - C432 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7236 In-Line Connector Faces - C455 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7237 In-Line Connector Faces - C917 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7238 In-Line Connector Faces - C921 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7239 In-Line Connector Faces - C921 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7240 In-Line Connector Faces - C921 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7241 In-Line Connector Faces - C922 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7242 In-Line Connector Faces - C941 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay Power Distribution Relay: Locations Trailer Tow Backup Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7247 Power Distribution Relay Box The Trailer Tow Backup Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7248 Power Distribution Relay: Locations Trailer Tow Battery Charge Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7249 Power Distribution Relay Box The Trailer Tow Battery Charge Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7250 Power Distribution Relay: Locations Trailer Tow Left Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7251 Power Distribution Relay Box The Trailer Tow Left Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7252 Power Distribution Relay: Locations Trailer Tow Right Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7253 Power Distribution Relay Box The Trailer Tow Right Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7254 Power Distribution Relay: Locations Trailer Tow Running Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7255 Power Distribution Relay Box The Trailer Tow Running Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay Power Distribution Relay: Locations Trailer Tow Backup Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7261 Power Distribution Relay Box The Trailer Tow Backup Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7262 Power Distribution Relay: Locations Trailer Tow Battery Charge Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7263 Power Distribution Relay Box The Trailer Tow Battery Charge Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7264 Power Distribution Relay: Locations Trailer Tow Left Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7265 Power Distribution Relay Box The Trailer Tow Left Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7266 Power Distribution Relay: Locations Trailer Tow Right Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7267 Power Distribution Relay Box The Trailer Tow Right Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7268 Power Distribution Relay: Locations Trailer Tow Running Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 7269 Power Distribution Relay Box The Trailer Tow Running Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block Relay Box: Locations Blower/Flasher Relay Block Instrument Panel View The Blower/Flasher Relay Block is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 7274 Relay Box: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 7275 Relay Box: Locations Regular Production Option Relay Block Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Blower/Flasher Relay Block Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7278 Lock Relays Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7279 Power Distribution Relay Box Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7280 RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block Relay Box: Locations Blower/Flasher Relay Block Instrument Panel View The Blower/Flasher Relay Block is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 7285 Relay Box: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 7286 Relay Box: Locations Regular Production Option Relay Block Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Blower/Flasher Relay Block Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7289 Lock Relays Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7290 Power Distribution Relay Box Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7291 RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7297 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7298 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7299 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7300 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7301 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7302 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7303 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7304 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7305 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7306 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7307 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7308 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7309 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7310 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7311 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7312 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7313 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7314 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7315 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7316 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7317 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7318 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7319 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7320 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7321 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7322 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7323 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7324 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7325 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7326 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7327 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7328 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7329 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7330 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7331 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7332 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7333 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7334 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7335 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7336 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7337 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7338 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7339 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7340 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7341 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7342 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7343 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7344 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7345 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7346 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7347 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7348 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7349 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7350 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7351 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7352 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7353 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7354 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7355 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7356 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7357 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7358 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7359 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7360 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7361 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7362 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7363 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7364 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7365 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7366 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7367 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7368 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7369 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7370 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7371 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7372 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7373 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7374 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7375 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7376 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7377 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7378 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7379 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7380 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7381 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7382 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7383 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7384 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7385 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7386 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7387 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7388 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7389 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 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. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7390 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 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. 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 the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7391 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7392 Alignment: Technical Service Bulletins Alignment - Toe Setting Procedure Tip Article No. 98-16-9 08/17/98 STEERING - ALIGNMENT - TOE SET PROCEDURE - SERVICE TIP LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250, NAVIGATOR ISSUE It may be difficult to set toe with the jam nut tie rod sleeve while performing an alignment on some vehicles. This may be caused by the toe adjusting sleeve moving when the opposing jam nut is torqued. ACTION Refer to the following Service Procedure to ensure complete and accurate toe set/alignment by preventing the jam nut from backing off during the toe set procedure. SERVICE PROCEDURE When adjusting toe on 1997-98 F-150/F-250, Expedition, or Navigator, follow this procedure on each side of the vehicle when tightening the jam nuts. 1. Set toe to specification. 2. Make sure the inner and outer ball joint sockets are centered perpendicular to their studs. 3. Prevent the adjuster sleeve from rotating by securing it with a tool (pipe wrench or vise grip) against the lower control arm. 4. Torque one (1) jam nut to 90 Nm (66 lb-ft). 5. Paint a line across the adjuster sleeve and the torqued jam nut and another line across the torqued jam nut and tie rod threads. 6. With the wrench still preventing the adjuster sleeve from rotating, torque the other jam nut to 90 Nm (66 lb-ft). 7. Inspect the paint lines to be sure no relative movement of the adjuster sleeve, jam nut, or tie rod occurred. 8. If movement is detected or toe is no longer within specification, loosen both jam nuts, reset toe if necessary, and repeat procedure. 9. Repeat procedure for other side of vehicle. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 303000, 390000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7393 Alignment: Specifications BASE SUSPENSION ALIGNMENT Caster LH ........................................................................................................................................................ ....................................................... 5.1° ± 1.0° RH ............................................................................. .................................................................................................................................. 5.6° ± 1.0° Total/Split ............................................................................................................................................. ..................................................... -0.5° ± 0.7° Camber LH ........................................................................................................................................................ ...................................................... -0.2° ± 0.7° RH ............................................................................. ................................................................................................................................ -0.2° ± 0.7° Total/Split ............................................................................................................................................. ...................................................... 0.0° ± 0.7° Toe LH ........................................................................................................................................................ ................................................................ 0.15° RH ............................................................................. .......................................................................................................................................... 0.15° Total/Split ............................................................................................................................................. ................................................. -0.30° ± 0.25° AIR SUSPENSION ALIGNMENT (TRIM POSITION) Caster LH ........................................................................................................................................................ ....................................................... 5.0° ± 1.0° RH ............................................................................. .................................................................................................................................. 5.5° ± 1.0° Total/Split ............................................................................................................................................. ..................................................... -0.5° ± 0.7° Camber LH ........................................................................................................................................................ ...................................................... -0.4° ± 0.4° RH ............................................................................. ................................................................................................................................ -0.4° ± 0.4° Total/Split ............................................................................................................................................. ...................................................... 0.0° ± 0.7° Toe LH ........................................................................................................................................................ ................................................................ 0.10° RH ............................................................................. .......................................................................................................................................... 0.10° Total/Split ............................................................................................................................................. ................................................. -0.20° ± 0.25° RIDE HEIGHT Rear Curb Ride Height: Without Air Suspension .................................................................................................................................................... 218-242 mm (8.6-9.5 inch) With Air Suspension ......................................................................................................................................................... 168-178 mm (6.6-7.0 inch) Vehicle Lean Specifications Max. Allowable Variance, Front ...................................................................................................................................................... 16 mm (5/8 inch) Max. Allowable Variance, Rear ....................................................................................................................................................... 19 mm (3/4 inch) Ride Height Measurement Original Components Base Suspension ............................................................................................................................................................ 102-132 mm (4.02-5.20 inch) Air Suspension Ignition Off (Kneel Position) ................................................................................................................... 60-87 mm (2.36-3.42 inch) Ride Height, Original Components Base Suspension ............................................................................................................................................................ 107-113 mm (4.21-4.44 inch) Air Suspension Ignition Off (Kneel Position) ..................................................................................................................... 76-82 mm (3.0-3.23 inch) Ride Height, New Components Base Suspension ............................................................................................................................................................ 122-128 mm (4.80-5.04 inch) Air Suspension Ignition Off (Kneel Position) ..................................................................................................................... 76-82 mm (3.0-3.23 inch) Rear Vehicle Height [a] ................................................................................................................................................. 144.8-148.8 mm (5.7-5.8 inches) [a] From Bottom Of Frame To Rear Jounce Bumper Bolt Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7394 Alignment: Locations Wheel Alignment Adjusting Locations, Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7395 Alignment: Description and Operation Wheel Alignment Adjusting Locations, Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7396 DESCRIPTION Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting bolts. Toe is adjusted by the use of the front wheel spindle tie rod adjusting sleeve. The three basic alignment angles are camber, caster and toe. Camber and toe affect tire wear and directional stability, caster affects directional stability only. Camber, caster and toe settings change when the vehicle is loaded. The specifications given are static settings with the vehicle unloaded. CAMBER Camber is the inward or outward tilting of the wheels at the top. When the wheels tilt out at the top the camber is positive (+). When the wheels tilt in at the top the camber is negative (-). The amount of camber is measured in degrees from vertical. Steering axis inclination (included angle) is the center line drawn through the ball joints when viewed from the front. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7397 CASTER Caster is the tilting of the steering axis either forward or backward from vertical. A backward tilt is positive (+) and a forward tilt is negative (-). TOE Toe is a measurement of how much the front of the wheels are turned in or out from the straight-ahead position. When the wheels are turned in, toe is positive (+)(toe in). When the wheels are turned out, toe is negative (-)(toe out). Toe is measured in degrees, from side to side and totaled. Toe should only be checked and adjusted after the camber and caster have been set to the proper specifications. Wheel Track Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7398 WHEEL TRACK By design the vehicle has a front track that is wider at the front than the rear. Front track is the distance between the two front tires; rear track is the distance between the two rear tires. Dogtracking DOGTRACKING Dogtracking is the condition where the rear axle is not square to the chassis. Heavily crowned roads may give the illusion of dogtracking. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber Alignment: Service and Repair Caster and Camber 1. Loosen the upper suspension arm nuts to a point where the joints are snug. 2. To increase caster and camber, use the following steps. (1) To increase caster, move the front of the front suspension upper arm outboard and move the rear of the front suspension upper arm inboard. (2) To increase camber, move the front suspension upper arm outboard equally. NOTE: A pry bar can be used between the front suspension upper arm and the frame pocket to aid in moving the arm. 3. To decrease caster and camber, use the following steps. (1) To decrease caster, move the front of the front suspension upper arm inboard and move the rear of the front suspension upper arm outboard. (2) To decrease camber, move the front suspension on upper arm inboard equally. 4. Set the caster and camber to specifications. - If a caster increase of 0.9 degree is required, move the front of the front suspension upper arm outboard by 3 notches and move the rear of the front suspension upper arm inboard by 3 notches. NOTE: Each increment of the notches on the frame pocket represents 0.3 degree. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber > Page 7401 5. Tighten the upper suspension arm nuts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber > Page 7402 Alignment: Service and Repair 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 by attaching, a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings; follow manufacturer's instructions. 4. Hold the tie rod end while loosening the toe set jam nuts. 5. Rotate the front wheel spindle tie rod adjusting sleeve to desired position. 6. Tighten the toe set jam nuts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber > Page 7403 NOTE: Whenever the toe set jam nuts are loosened for toe adjustment, the nut and tie rod threads must be cleaned and lubricated. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Instrument Panel View The Electronic Variable Orifice Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 7409 Electronic Variable Orifice Steering Module (Without Air Suspension) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 7410 Steering Control Module: Description and Operation Vehicles with air suspension use the air suspension control module to monitor steering control for the Electronic Variable Orifice (EVO) steering system. Vehicles with base suspension use the EVO control module to monitor the steering system. Both systems on a panic or aggressive turn will provide additional power assist. If there is any electrical system failure in the EVO system the system will default to full power assist. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations Engine View The Air Suspension Solid State Compressor Relay is located near the right headlamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 7415 Compressor/Pump Relay: Description and Operation The compressor relay is energized by the control module to have high current flow from the battery to the compressor motor. - A Solid State Relay is used in the air suspension system for compressor control. The relay incorporates a custom power MOSFET and ceramic hybrid circuitry. The relay switches high current loads in response to low power signals and is controlled by the logic of the control module. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7424 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7425 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: All Technical Service Bulletins Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7435 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7436 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: Customer Interest Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7441 Suspension Control Module: Locations Instrument Panel View The 4 Wheel Air-Suspension Module is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7442 Suspension Control Module: Diagrams 4 Wheel Air Suspension Module (C295) 4 Wheel Air Suspension Module (C296) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7443 Suspension Control Module: Description and Operation A microcontroller-based electronic air suspension control module controls the air compressor motor (through a solid state relay), and all system solenoids. The air suspension control module also provides power to front and rear height sensors. The air suspension control module controls vehicle height adjustments by monitoring the two height sensors, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals, and the Brake Pedal Position (BPP) switch. The air suspension control module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing of the vehicle and related components. The air suspension control module is mounted in the passenger compartment inside the instrument panel, above the radio and temperature controls. The air suspension control module is interchangeable between the RAS and 4WAS system. The air suspension control module monitors and controls the system through a 32-pin two-way connector. The air suspension control module is keyed so that it cannot be plugged into an incorrect harness. There are two sides of the harness connection to the air suspension control module. Each is uniquely colored and keyed to prevent reversing the connections. NOTE: - The 4-Wheel Air Suspension (4WAS) control module is also used for the Rear Air Suspension (RAS) system. The internal processor recognizes external circuitry to determine if it is installed in a 4WAS or a RAS system. - The air suspension control module is calibrated with information from the air suspension height sensors. A new or swapped air suspension control module requires the ride height adjustment calibration process to be performs Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7444 Suspension Control Module: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. Remove the center instrument panel finish panel. 4 3. Disconnect the transfer case rotary control switch electrical connector. 4. Remove the steering column cover trim panel. 5. Remove the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7445 6. Remove the LH instrument panel finish panel. (1) Remove the seven bolts. (2) Disconnect the electrical connector. (3) Remove the instrument panel finish panel. 7. Remove the instrument cluster panel. (1) Remove the five screws. (2) Disconnect the four electrical connectors. (3) Remove the instrument cluster panel. 8. Remove the air suspension control module screws. 9. Remove the air suspension control module. (1) Disconnect the electrical connectors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7446 (2) Remove the air suspension control module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. - The air suspension control module is calibrated with information from the ride height sensor. A new or exchanged air suspension control module requires that the ride height adjustment calibration process be performed; refer to Front Ride Height Resetting-Clear B2140 DTC. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Description and Operation Steering Angle Sensor: Description and Operation The steering sensor is mounted inside the passenger compartment on the steering column. It provides steering rate and position to the control module through two signals. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Description and Operation > Page 7452 Steering Angle Sensor: Service and Repair REMOVAL 1. Remove the steering column. 2. Remove the shock absorber electronic steering sensor. (1) Disconnect the electrical connector. (2) Remove the screws. (3) Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. (1) Remove the steering column lower bearing spring. (2) Remove the sensor ring. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Description and Operation > Page 7453 2. Install the shock absorber electronic steering sensor. (1) Position the shock absorber electronic steering sensor. (2) Install the screws. (3) Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Electrical Specifications Ride Height Sensor: Electrical Specifications GENERAL SPECIFICATIONS Rear Height Sensor Voltage ................................................................................................................ .................................................... 2.66 ± 0.02 volts Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Electrical Specifications > Page 7459 Ride Height Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Ball Stud Nut ........................................................................................................................................ .......................... 10.2-13.8 Nm (91-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front Ride Height Sensor: Locations Front Body View The Front Height Sensor is located behind the left running board. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front > Page 7462 Ride Height Sensor: Locations Rear Body View The Rear Height Sensor is located under left rear of vehicle near the axle housing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 7463 Ride Height Sensor: Description and Operation Two height sensors are mounted on the vehicle. The sensors send a voltage signal to the control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce), to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensors have a useable range of 80 mm (3 in) compared to total suspension travel of 200-250 mm (8-10 in) at the wheel. Therefore, the sensors are mounted to the suspension at a point where full suspension travel at the wheel is relative to 80 mm (3 in) of travel at the height sensor. The front height sensor upper socket is attached to the bracket to the frame at the upper control arm mounting area and the lower height sensor socket is attached to the upper control arm bracket. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace a sensor as a unit. When the height sensor indicates that the vehicle is lower than trim under normal driving conditions, the air compressor will turn on and pump compressed air to the system. When the sensor indicates that the vehicle is raised above trim under normal driving conditions, this will cause the air to be vented from the system to lower the vehicle to its trim height level. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 7464 Ride Height Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Remove the air suspension height sensor. (1) Disconnect the electrical connector. (2) Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. NOTE: - Rear height sensor shown; front similar. - The air suspension has a plastic harness retainer that must be unclipped prior to removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Description and Operation Steering Angle Sensor: Description and Operation The steering sensor is mounted inside the passenger compartment on the steering column. It provides steering rate and position to the control module through two signals. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Description and Operation > Page 7468 Steering Angle Sensor: Service and Repair REMOVAL 1. Remove the steering column. 2. Remove the shock absorber electronic steering sensor. (1) Disconnect the electrical connector. (2) Remove the screws. (3) Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. (1) Remove the steering column lower bearing spring. (2) Remove the sensor ring. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Description and Operation > Page 7469 2. Install the shock absorber electronic steering sensor. (1) Position the shock absorber electronic steering sensor. (2) Install the screws. (3) Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications TORQUE SPECIFICATIONS Bracket Mounting Bolt ................................................................................................................................................... 10.2-13.8 Nm (92-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 7473 Suspension Mode Switch: Locations The air suspension switch is located behind the RH kick panel on a mounting bracket. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 7474 Suspension Mode Switch: Description and Operation The air suspension switch is located behind the RH kick panel on a mounting bracket. The switch interrupts power to the control module. The air suspension switch supplies a signal to the control module. Without the control module receiving this signal the load leveling system is inoperative and will not react when rear of the vehicle is raised or lowered. If the air suspension is disabled by turning off air suspension switch, a "CHECK SUSP" will appear in the RH corner of the cluster with the ignition in the run position. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 7475 Suspension Mode Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 7476 5. Remove the air suspension switch bracket mounting bolt. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications Center Link: Specifications TORQUE SPECIFICATIONS Drag Link To Idler Arm Castellated Nut ................................................................................................................................. 77-103 Nm (56-75 ft. lbs.) Drag Link To Sector Shaft Castellated Nut .............................................................................................................................. 77-103 Nm (56-75 ft. lbs.) Drag Link To Inner Tie Rod End Castellated Nut .................................................................................................................................... ............................... 77-103 Nm (56-75 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications > Page 7481 Center Link: Service and Repair REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the steering sector shaft arm drag link castellated nuts. (1) Remove the cotter pins. (2) Remove the castellated nuts. 3. Remove the tie rod end from the steering sector shaft arm drag link. Use Remover to separate the steering sector shaft arm drag link from RH and LH tie rod ends. 4. Remove the steering sector shaft arm drag link. - Use Pitman Arm Puller to remove the steering sector shaft arm drag link. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications > Page 7482 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Diagnostic Connector, Steering > Component Information > Locations Diagnostic Connector: Locations Instrument Panel View The Electronic Variable Orifice Diagnostic Connector is located behind the right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Diagnostic Connector, Steering > Component Information > Locations > Page 7486 EVO Test Connector Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications Idler Arm: Specifications TORQUE SPECIFICATIONS Steering Idler Arm And Bracket To Frame Bolt .............................................................................................................................................. 170-230 Nm (125.5-169 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 7490 Idler Arm: Service and Repair REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MARY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the steering sector shaft arm drag link castellated nuts. (1) Remove the cotter pins. (2) Remove the castellated nuts. 3. Use Pitman Arm Puller to separate the steering sector shaft arm drag link. 4. Remove the steering idler arm and bracket. (1) Remove the bolts. (2) Remove the steering idler arm and bracket. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 7491 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications Pitman Arm: Specifications TORQUE SPECIFICATIONS Sector Shaft Arm Drag Link Castellated Nut .......................................................................................................................................................... 77-103 Nm (57-75 ft. lbs.) Sector Shaft Arm Nut ......................................................................................................................................................... 234-316 Nm (173-233 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair NOTE: If the air is not purged from the power steering system correctly, pump failure could result. This condition can occur on pre-delivery vehicles with evidence of aerated fluid or on vehicles that have had steering component repairs. A whine heard from the power steering pump may be caused by air in the system. The power steering air purge procedure must be performed under the following conditions: - Prior to any component repair for which power steering noise complaints are accompanied by evidence of aerated fluid. - After replacement of any power steering system component (gear, hose, etc.). 1. Remove the fluid reservoir cap. 2. Tightly insert the stopper of the vacuum pump into the fluid reservoir. 3. Start the engine and allow it to idle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 7499 4. Apply maximum vacuum for a minimum of three minutes at idle. Maintain maximum vacuum with the source. 5. Release the vacuum and remove the vacuum source. 6. Add fluid to the center mark of the power steering fluid reservoir. 7. Reinstall the vacuum source and apply maximum vacuum. 8. Cycle the steering wheel from stop to stop every 30 seconds for approximately five minutes. CAUTION: Do not hold the steering wheel in the far left or right position or damage to power steering may result. 9. Stop the engine, release the vacuum, and remove the vacuum source. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 7500 10. Add fluid if necessary. Install the fluid reservoir cap. 11. Start the engine and cycle the steering wheel from stop to stop every 30 seconds for approximately five minutes. CAUTION: Do not hold the steering wheel in the far left or right position or damage to power steering may result. 12. Check for power steering fluid leaks at all connections. If the power steering fluid still shows signs of aeration, repeat this procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 7505 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Fill to line in power steering fluid reservoir. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 7508 Power Steering Fluid: Fluid Type Specifications FLUID TYPE ........................................................................................................................................................... Ford E6AZ-19582-AA or equivalent Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications Power Steering Fluid Cooler: Specifications TORQUE SPECIFICATIONS Power Steering Fluid Cooler Bolts ......................................................................................................................................... 9-12 Nm (80-107 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications > Page 7512 Power Steering Fluid Cooler: Service and Repair REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. If equipped, remove the skid plate. (1) Remove the bolts. (2) Remove the skid plate. 3. Remove the lower radiator air deflector (1) Remove the screws. (2) Remove the push clips. (3) Remove the lower radiator air deflector. 4. Disconnect the power steering fluid cooler hoses. (1) Compress and slide the clamps back. (2) Disconnect the hoses. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications > Page 7513 5. Remove the power steering fluid cooler. (1) Remove the bolts. (2) Remove the fluid cooler. INSTALLATION 1. To install, reverse the removal procedure. 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Mechanical Specifications Power Steering Fluid Reservoir: Mechanical Specifications TORQUE SPECIFICATIONS Reservoir Bracket Bolts To Exhaust Manifold .......................................................................................................................... 68-92 Nm (50-67 ft. lbs.) Upper Reservoir Bracket Bolt ................................................................................................................................................ 9-12 Nm (80-107 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Mechanical Specifications > Page 7518 Power Steering Fluid Reservoir: Pressure, Vacuum and Temperature Specifications Air Purge Vacuum ............................................................................................................................... ........................................... 68-85 kPa (20-25 in-Hg) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Page 7519 Power Steering Fluid Reservoir: Service and Repair REMOVAL 1. Remove the three bolts. Position the power steering pump reservoir aside. 2. Disconnect the hoses. Drain the power steering system. 3. Remove the power steering pump reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications TORQUE SPECIFICATIONS Power Steering Pressure Hose Fitting ........................................................................................................................................ 17-23 Nm (13-17 ft. lbs.) Power Steering Return Hose Fitting ........................................................................................................................................... 17-23 Nm (13-17 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose Power Steering Line/Hose: Service and Repair Low Pressure Hose REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the power steering low pressure hose. Drain the power steering system. 3. Lower the vehicle. 4. Disconnect and remove the power steering low pressure hose. INSTALLATION 1. Follow the removal procedure in reverse order 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 7525 Power Steering Line/Hose: Service and Repair Pressure Hose REMOVAL 1. Prepare the vehicle for power steering pressure hose removal. (1) Remove the fan and shroud. (2) Remove the drive belt. 2. Disconnect the power steering pressure hose. Drain the power steering system. 3. Remove the power steering pump pulley using the Power Steering Pump Pulley Remover 4. Disconnect and remove the power steering pressure hose. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 7526 1. Install a new seal on the power steering pressure hose at the power steering pump end. - Remove and discard the original seal. - Stretch the seal over the Seal Replacer until it is large enough to slip over the tube nut. 2. Route the power steering pressure hose in the vehicle. Connect the power steering pressure hose. 3. Install the power steering pump pulley. - Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks, replace the pulley. If there is no paint or one paint mark, use a paint pencil to mark the web area of the pulley near the hub. - Use the Power Steering Pump Pulley Replacer. CAUTION: Replacement of the power steering pump pulley is necessary after being removed and installed two times. 4. Connect the power steering pressure hose. 5. Restore the vehicle to operating condition. (1) install the drive belt. (2) Install the fan and shroud. (3) Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 7527 Power Steering Line/Hose: Service and Repair Pump Reservoir Hose REMOVAL 1. Prepare the vehicle for power steering reservoir pump hose removal. (1) Remove the fan and shroud. (2) Remove the drive belt. 2. Remove the three bolts. 3. Disconnect the power steering reservoir pump hose. Drain the power steering system. 4. Remove the nuts and belt deflector 5. Remove the two bolts. 6. Raise and support the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 7528 WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 7. Disconnect the Electronic Variable Orifice (EVO) power steering control valve actuator electrical connector. 8. Remove the bolt. 9. Lower the vehicle. 10. Position the power steering pump forward. 11. Disconnect and remove the power steering reservoir pump hose. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 7529 1. Route the power steering reservoir pump hose in the vehicle. Connect the power steering reservoir pump hose. 2. Position the power steering pump. 3. Loosely install the bolts. 4. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 5. Install the bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 7530 6. Connect the EVO power steering control valve actuator electrical connector. 7. Lower the vehicle. 8. Tighten the bolts. 9. Install the belt deflector and nuts. 10. Connect the power steering reservoir pump hose. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 7531 11. Position the power steering pump reservoir. Install the three bolts. 12. Restore the vehicle to operating condition. (1) Install the drive belt. (2) Install the fan and shroud. (3) Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 7532 Power Steering Line/Hose: Service and Repair Return REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the power steering return hose. Drain the power steering system. 3. Lower the vehicle. 4. Disconnect and remove the power steering return hose. INSTALLATION 1. Follow the removal procedure In reverse order 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Page 7533 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications TORQUE SPECIFICATIONS Power Steering Pump Lower Bolt .............................................................................................................................................. 20-30 Nm (15-20 ft. lbs.) Power Steering Pump Upper Bolts ............................................................................................................................................. 20-30 Nm (15-20 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 7538 Power Steering Pump: Pressure, Vacuum and Temperature Specifications GENERAL SPECIFICATIONS Flow ..................................................................................................................................................... ........... 3.0 ± 0.2 gpm @ 50 psi & 2500 pump rpm Minimum Capacity ............................................... ................................................................................................................................ 1.4 gpm @ 750 psi Relief Pressure .............................................................................................................................. .............................................................. 1300-1430 psi Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 7539 Power Steering Pump: Description and Operation NOTE: Earlier builds have four bolts mounting the power steering pump to the engine block. The fourth lower bolt behind the pulley on earlier builds may be discarded upon removal of the power steering pump. The CIII power steering pump has the following features: - It is a belt-driven, vane-type, power steering pump. - It is mounted directly to the engine block by three bolts. - The power steering pump is replaced as an assembly. - The identification tag attached to the power steering pump indicates the model number and bar code. Refer to these when pump replacement is required. - The power steering pump uses a quick connect fitting for the power steering pressure hose. - The power steering fluid reservoir is mounted on the LH side of the engine. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 7540 Power Steering Pump: Testing and Inspection WARNING: DO NOT TOUCH THE FLOWMETER DURING THE TEST PROCEDURE OR SEVERE BURNS AND SERIOUS INJURY MAY OCCUR. 1. Install Power Steering Analyzer at the high pressure port of the power steering pump. Make sure the Power Steering Analyzer gate valve is fully open. On some vehicles, the power steering pump high pressure port is inaccessible; Power Steering Analyzer should then be installed either at the steering gear or at a point in the high pressure line between the power steering pump and the steering gear. CAUTION: Ensure that the connection point will not interfere with any of the engine accessory drive components or drive belts. 2. Place Dial Thermometer in the power steering pump reservoir. 3. Check the power steering fluid level. If necessary, add power steering fluid. - Use Motorcraft MERCON Multi-Purpose ATE XT-2-QDX or equivalent meeting Ford specification MERCON. 4. Install 88 Digital Multimeter. 5. Start the engine. Place the transmission in N (neutral). Set the parking brake. Raise the power steering fluid temperature to 74-80° C (165-175° F) by rotating the steering wheel fully to the left and right several times. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. 6. Set the engine speed to idle. Record the flow rate and pressure readings. - If flow rate is below the idle flow rate specification, the power steering pump may require repair. Continue with the test procedure. - If the pressure reading is above the idle pressure specification, then check power steering hoses for kinks and restrictions. 7. Partially close the gate valve to obtain 740 psi. Record the flow rate - If the flow rate is less than specification, replace the power steering pump. 8. Completely close and partially open the gate valve three times. Record the pressure relief valve actuation pressure reading. - If pressure does not meet the relief pressure specification, then replace the power steering pump. CAUTION: Do not allow the gate valve to remain closed for more than five seconds. 9. Set the engine speed to 1500 rpm. Record the flow rate. - If the flow rate varies more than 3.785 liters/minute (1 gallon/minute) between the initial flow rate reading, then replace the power steering pump. 10. Set the engine speed at idle. Turn the steering wheel to the left and right stops. Record flow rate and pressure readings at the stops. - The pressure reading at both stops should be nearly the same as the maximum pump relief pressure. - The flow rate should drop below 1.9 liters/minute (0.5 gallons/minute). - If the pressure does not reach the maximum pump relief pressure or the flow rate does not drop below the specified value, excessive internal leakage is occurring. Replace the steering gear. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. 11. Turn the steering wheel slightly in both directions and release quickly while watching the pressure gauge. - The pressure reading should move between the normal back pressure reading and snap back as the steering wheel is released. - If the pressure returns slowly or sticks, the rotary valve in the steering gear is sticking or the steering column is binding. Check the steering column and linkages before repairing the steering gear. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump REMOVAL 1. Prepare the vehicle for power steering pump removal. (1) Remove the fan and shroud. (2) Remove the drive belt. 2. Remove the three bolts. Position the power steering pump reservoir aside. 3. Disconnect the power steering reservoir pump hose. Drain the power steering pump supply line. 4. Disconnect the power steering pressure hose. Drain the power steering system. 5. Remove the nuts and belt deflector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7543 6. Remove the two bolts. 7. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION MUST BE SHUT OFF PRIOR TO HOISTING JACKING OR TOWING AN AIR SUSPENSION VEHICLE, THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 8. If equipped, remove the skid plate, (1) Remove the bolts. (2) Remove the skid plate. 9. Disconnect the Electronic Variable Orifice (EVO) power steering control valve actuator electrical connector. 10. Remove the bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7544 11. Lower the vehicle. 12. Remove the power steering pump. 13. Remove the power steering reservoir pump hose and the power steering pressure hose. 14. Position the power steering pump in a vise. Remove the power steering pump pulley using the Power Steering Pump Pulley Remover. 15. Remove the pump from the vise. INSTALLATION 1. Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks, replace the pulley. If there is no paint or one paint mark, use a paint pencil to mark the web area of the pulley near the hub. Position the power steering pump in a vise. Install the power steering pump pulley Use the Power Steering Pump Pulley Replacer. - Remove the pump from the vise Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7545 CAUTION: Replacement of the power steering pump pulley is necessary after being removed and installed two times. 2. Install a new seal on the power steering pressure hose at the power steering pump end. - Remove and discard the original seal. - Stretch the seal over the Seal Replacer until it is large enough to slip over the tube nut. 3. Install the power steering reservoir pump hose and the power steering pressure hose. 4. Position the power steering pump in the vehicle. 5. Loosely install the two bolts. 6. Raise and support the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7546 7. Install the bolt. 8. Connect the EVO power steering control valve actuator electrical connector. 9. If equipped, install the skid plate. (1) Position the skid plate. (2) Install the bolts. 10. Lower the vehicle. 11. Tighten the two bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7547 12. Install the belt deflector and nuts. 13. Connect the power steering pressure hose. 14. Connect the power steering reservoir pump hose. 15. Position the power steering oil reservoir. Install the three bolts. 16. Restore the vehicle to operating condition. (1) Install the drive belt. (2) Install the fan and shroud. (3) Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7548 Power Steering Pump: Service and Repair Power Steering Pump Pulley REMOVAL 1. Prepare the vehicle for power steering pump pulley removal. (1) Remove the fan and shroud. (2) Remove the drive belt. 2. Remove the power steering pump pulley using the Power Steering Pump Pulley Remover. INSTALLATION 1. Install the power steering pump pulley. - Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks, replace the pulley. If there is no paint or one paint mark, use a paint pencil to mark the web area of the pulley near the hub. - Use the Power Steering Pump Pulley Replacer. CAUTION: Replacement of the power steering pump pulley is necessary after being removed and installed two times. 2. Restore the vehicle to operating condition. (1) Install the drive belt. (2) Install the fan and shroud. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Tools and Equipment > Power Steering Pump Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Tools and Equipment > Power Steering Pump > Page 7551 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Instrument Panel View The Electronic Variable Orifice Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 7555 Electronic Variable Orifice Steering Module (Without Air Suspension) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 7556 Steering Control Module: Description and Operation Vehicles with air suspension use the air suspension control module to monitor steering control for the Electronic Variable Orifice (EVO) steering system. Vehicles with base suspension use the EVO control module to monitor the steering system. Both systems on a panic or aggressive turn will provide additional power assist. If there is any electrical system failure in the EVO system the system will default to full power assist. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Instrument Panel View The Electronic Variable Orifice Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 7561 Electronic Variable Orifice Steering Module (Without Air Suspension) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 7562 Steering Control Module: Description and Operation Vehicles with air suspension use the air suspension control module to monitor steering control for the Electronic Variable Orifice (EVO) steering system. Vehicles with base suspension use the EVO control module to monitor the steering system. Both systems on a panic or aggressive turn will provide additional power assist. If there is any electrical system failure in the EVO system the system will default to full power assist. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Description and Operation Steering Angle Sensor: Description and Operation The steering sensor is mounted inside the passenger compartment on the steering column. It provides steering rate and position to the control module through two signals. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Description and Operation > Page 7567 Steering Angle Sensor: Service and Repair REMOVAL 1. Remove the steering column. 2. Remove the shock absorber electronic steering sensor. (1) Disconnect the electrical connector. (2) Remove the screws. (3) Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. (1) Remove the steering column lower bearing spring. (2) Remove the sensor ring. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Description and Operation > Page 7568 2. Install the shock absorber electronic steering sensor. (1) Position the shock absorber electronic steering sensor. (2) Install the screws. (3) Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Description and Operation Steering Angle Sensor: Description and Operation The steering sensor is mounted inside the passenger compartment on the steering column. It provides steering rate and position to the control module through two signals. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Description and Operation > Page 7572 Steering Angle Sensor: Service and Repair REMOVAL 1. Remove the steering column. 2. Remove the shock absorber electronic steering sensor. (1) Disconnect the electrical connector. (2) Remove the screws. (3) Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. (1) Remove the steering column lower bearing spring. (2) Remove the sensor ring. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Description and Operation > Page 7573 2. Install the shock absorber electronic steering sensor. (1) Position the shock absorber electronic steering sensor. (2) Install the screws. (3) Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect the battery ground cable. WARNING: THE BACKUP POWER SUPPLY ENERGY MUST BE DEPLETED BEFORE ANY AIR BAG COMPONENT REPAIR IS PERFORMED. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the driver side air bag module from the vehicle. WARNING: PLACE THE AIR BAG MODULE ON A BENCH WITH THE TRIM COVER FACING UP TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 4. Connect the air bag simulator to the vehicle harness at the top of the steering column. 5. Remove the passenger side air bag module from the vehicle. WARNING: PLACE THE AIR BAG MODULE ON A BENCH WITH THE DEPLOYMENT DOOR FACING UP TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 6. Connect the air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Reactivation Procedure 1. Disconnect the battery ground cable. WARNING: THE AIR BAG SIMULATORS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. In stall the driver side air bag module. 5. Remove the air bag simulator from the vehicle harness connector at the passenger side air bag module. 6. Install the passenger side air bag module. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 8. Prove out the system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 7579 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Are both air bag sensors connected and mounted to the vehicle? [ ] 2. Is the three-way connector at the base of the steering column connected? [ ] 3. Are the air bag modules or air bag simulators connected? [ ] 4. Is the air bag diagnostic monitor connected? [ ] 5. Is the vehicle battery connected? [ ] Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the (A) ignition switch lock cylinder release tab while pulling out the (B) ignition switch lock cylinder. 3. Remove the key in ignition warning switch. 1 Pry the clip downward. 2 Release the key-in-ignition warning switch from the rear of the ignition switch lock cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Service and Repair > Page 7583 INSTALLATION 1. To install, reverse the removal procedure. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Specifications Steering Column Cover: Specifications TORQUE SPECIFICATIONS Instrument Panel Steering Column Cover Bolts ............................................................................................................................................... 2-3 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications GENERAL SPECIFICATIONS Ratio .................................................................................................................................................... ........................................................................ 14:1 Worm Bearing Preload ....................................... ................................................................................................................................ 0.9 Nm (8 inch lbs.) Total Meshload Over Worm Bearing Preload ........................................................................................................................... 0.45-1 Nm (4-9 inch lbs.) Steering Gear Meshload .............................................................................................................. ..................................................... 2.0 Nm (18 inch lbs.) Turns Of Steering Wheel (Lock To Lock Linkage Disconnected) ................................................................................................ ................................................................... 3.4 TORQUE SPECIFICATIONS Ball Guide Clamp Bolts .............................................................................................................................................................. 5-7 Nm (45-62 inch lbs.) Meshload Adjuster Lock Nut ..................................................................................................................................................... 26-35 Nm (19-26 ft. lbs.) Power Steering Gear Race Nut ................................................................................................................................................. 75-122 Nm (55-90 ft. lbs.) Sector Shaft Housing Cover Bolts ............................................................................................................................................. 61-75 Nm (45-55 ft. lbs.) Steering Gear Allen Head Race Lock Nut ......................................................................................................................... 1.7-2.8 Nm (15-24.9 inch lbs.) Steering Gear Bolts .............................................................................................................. ...................................................... 68-92 Nm (50-67 ft. lbs.) Valve Housing Bolts ............................. ..................................................................................................................................... 40-60 Nm (30-44 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7590 Steering Gear: Description and Operation Steering Gear - All Except Motorhome The steering gear has the following features: - It is a torsion-bar type hydraulic assisted system. - It reduces road shock and vibration. - It includes a rotary-style hydraulic valve. - It uses a dot matrix ID mark on the gear housing between the valve housing and the sector shaft housing cover. - It may have an optional identification tag mounted to the valve housing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7591 Steering Gear: Adjustments 1. Turn the steering wheel from right stop to left stop at least once. NOTE: The engine should not be running. 2. Remove the driver side air bag. 3. Raise and support the vehicle. 4. Remove the steering sector shaft arm drag link castellated nut. (1) Remove the cotter pin. (2) Remove the castellated nut. 5. Use Pitman Arm Puller to separate the steering sector shaft arm drag link. 6. Lower and support the front of the vehicle. NOTE: The front wheels should not touch the ground. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7592 7. Attach a inch lb torque wrench to the (A) bolt and measure the steering gear meshload from center. NOTE: Reset the steering gear meshload only if the measured rotating torque for total on-center load is less than specification. 8. Meshload adjustment is necessary if out of specification. 9. Remove the fan blade assembly and fan shroud to access the sector shaft locknut. 10. Adjust the sector shaft to proper rotating torque. (1) Hold the sector shaft and loosen the meshload adjuster locknut. (2) Adjust the sector shaft. 11. Verify that the rotating torque is to specification. - Readjust if necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7593 12. Tighten the meshload adjuster locknut. (1) Hold the sector shaft. (2) Tighten the locknut. 13. Install the steering sector shaft arm drag link castellated nut and cotter pin. (1) Position the steering sector shaft arm drag link. (2) Install the steering sector shaft arm drag link castellated nut. (3) Install a new cotter pin. 14. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 15. Install the fan blade assembly and fan shroud. 16. Install the driver side air bag. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement Steering Gear: Service and Repair Replacement REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the skid plates. (1) Remove the bolts. (2) Remove the skid plate. 3. Slide back the plastic cover from the intermediate steering shaft to the steering gear. 4. Remove the intermediate shaft pinch bolt and remove the intermediate steering shaft from the steering gear. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7596 5. Remove the steering shaft arm drag link castellated nut. (1) Remove the cotter pin. (2) Remove the castellated nut. 6. Use the Pitman Arm Puller to separate the steering sector shaft arm drag link. 7. Mark a reference point between the steering gear sector shaft and the steering gear housing. 8. Remove the steering gear to frame mounting bolts. Note the location of each bolt during removal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7597 9. Disconnect the power steering fluid return line. (1) Support the steering gear. (2) Slide back the spring clamp. (3) Disconnect the power steering fluid return line and allow the fluid to drain. CAUTION: Use care not to damage or bend the power steering cooler tubes. 10. Remove the pressure line from the steering gear and remove the steering gear from the vehicle. 11. Secure the steering gear in a vise. Remove the nut and lockwasher. 12. Use the Pitman Arm Puller to remove the steering gear sector shaft arm. - Note the position of the steering gear sector shaft arm. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7598 13. Remove the power steering fluid return line. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7599 1. Follow the removal procedure in reverse order. NOTE: The steering gear sector shaft arm to sector shaft nut must be installed and tightened to specification prior to installation of the steering gear for clearance purposes. 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7600 Steering Gear: Service and Repair Overhaul Disassembly NOTE: The steering gear input shaft and seals cannot be repaired or replaced separately. Gear replacement may be necessary. 1. Secure the steering gear in a vise with the indexing flat pointed down. Use protective caps on the vise Jaws. 2. Rotate the power steering gear input shaft and control from stop to stop and then center the gear 3. Remove the steering gear sector shaft housing cover bolts. 4. Tap on the lower end of the steering gear sector shaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7601 5. Remove the steering gear sector shaft. 6. Remove the locking nut from the steering gear sector shaft adjustment screw. 7. Remove the sector shaft housing cover. - Hold the steering gear sector shaft. - Turn the housing cover counterclockwise. 8. Remove the valve housing bolts and the identification tag. 9. Remove the valve housing and piston assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7602 10. Remove and discard the gasket. 11. Remove the ball bearings. (1) Remove the bolts. (2) Remove the steering gear hall return guide clamp. (3) Remove the steering gear ball return guide. (4) Rotate the piston over a container to collect the 28 steering gear worm balls. 12. Remove the input shaft valve and housing assembly from the piston. 13. Remove and discard the seal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7603 14. Install the valve housing in Bench Mounted Holding Fixture and loosen the setscrew. 15. Use Adjuster and Locknut Wrench to remove the race nut. 16. Remove the power steering gear input shaft and control from the valve housing. 17. Rotate the valve housing with Bench Mounted Holding Fixture. 18. Use Puller to remove the power steering gear input shaft seal dust seal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7604 19. Remove the input shaft snap ring. 20. Rotate the valve housing with Bench Mounted Holding Fixture and use Input Shaft Bearing/Seal Tool to remove the bearing and power steering gear input shaft seal. 21. Remove the valve housing from Bench Mounted Holding Fixture. 22. Install the steering gear housing in Bench Mounted Holding Fixture and remove the steering gear sector shaft dust seal from the sector shaft seal bore. 23. Remove the spacer. (1) Remove the snap ring. (2) Remove the spacer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7605 24. Use Puller to remove the sector shaft seal. NOTE: The steering gear sector shaft bearing is not replaceable. Assembly 1. Lubricate the sector shaft seal bore. - Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. 2. Use Sector Shaft Seal Replacer to install the sector shaft seals - Lubricate the sector shaft seal, use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. 3. Install the spacer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7606 4. Install the snap ring. 5. Use Sector Shaft Seal Replacer to install the sector shaft dust seal. - Lubricate the steering gear sector shaft dust seal; use Multi-Purpose Grease. DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. NOTE: Place the steering gear sector shaft dust seal on Sector Shaft Seal Replacer so the raised lip is toward the tool. 6. Remove the steering gear housing from Bench Mounted Holding Fixture. 7. Position the input shaft bearing in the valve housing and use Input Shaft Bearing/Seal Tool Set and a press to seat the bearings 8. Use Input Shaft Bearing/Seal Tool and a press to seat the power steering gear input shaft seal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7607 9. Install the input shaft snap ring. 10. Use Input Shaft Bearing/Seal Tool to install the power steering gear input shaft dust seal. 11. Mount the valve housing in Bench Mounted Holding Fixture. 12. Install the power steering gear input shaft and control into the valve housing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7608 13. Position the power steering gear race nut into the valve housing. 14. Use Adjuster and Locknut Wrench to tighten the race nut. 15. Install the setscrew. 16. Remove the valve housing from Bench Mounted Holding Fixture and position the piston on the worm gear. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7609 17. Install the steering gear ball return guide on the piston. WARNING: HOLD THE BALL RETURN GUIDES UNTIL THE CAP OR CLIP IS REINSTALLED FAILURE TO HOLD THE GUIDES WILL RESULT IN A TRAPPED BALL OR BALLS, WHICH COULD CAUSE A VEHICLE ACCIDENT. IF THE BALL GUIDES BECOME UNSEATED AT ANY TIME, REMOVE ALL THE BALLS AND REPEAT THE PROCEDURE. 18. Rotate the piston while holding the steering gear ball return guide and install the 28 ball bearings into the opening in the ball guide. WARNING: - THE CORRECT NUMBER OF BALLS ARE REQUIRED FOR PROPER GEAR OPERATION. COUNT THE BALLS AND INSERT EACH CAREFULLY. - TO MAKE SURE THE BALLS ARE PROPERLY INSTALLED, ROTATE THE STEERING GEAR INPUT WORM GEAR AND RACK FROM ONE END OF TRAVEL TO THE OTHER WITHOUT ALLOWING THE POPPET ADJUSTER TO CONTACT THE VALVE HOUSING OR MOVING THE VALVE HOUSING PILOT FACE MORE THAN 69.1 MM (2-3/4 INCHES) FROM THE INPUT END OF THE RACK PISTON. IF THE STEERING GEAR INPUT WORM GEAR AND RACK CANNOT BE ROTATED, REINSTALL THE BALLS. IF A STEERING GEAR IS INSTALLED WITH A STEERING GEAR INPUT WORM GEAR AND RACK THAT CANNOT ROTATE, THE STEERING GEAR WILL NOT FUNCTION CORRECTLY AND STEERING AND GEAR FAILURE CAN RESULT. 19. Install the steering gear ball return guide clamp. (1) Position the steering gear ball return guide clamp. (2) Install the bolts Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7610 20. Install a new gasket. 21. Lubricate and install the seal on the piston. - Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. 22. Install the piston assembly into the steering gear housing. NOTE: Make sure to align the oil passages in the steering gear housing. 23. Rotate the teeth so they are on the same plane as the steering gear sector shaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7611 24. Loosely install the valve housing bolts and the identification tag, if so equipped. 25. Lubricate the O-ring on the sector shaft housing cover. - Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. 26. Rotate the housing clockwise and install the sector shaft into the sector shaft housing. 27. Install the sector shaft lock nut. NOTE: The sector shaft lock nut will be tightened during the steering gear meshload adjustment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7612 28. Install the sector shaft and housing assembly. NOTE: Loosely install the sector shaft housing bolts. 29. Tighten the bolts. 30. Tighten the bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 7613 Steering Gear: Tools and Equipment Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications Steering Shaft: Specifications TORQUE SPECIFICATIONS Intermediate Shaft Pinch Bolt .................................................................................................................................................... 40-54 Nm (30-40 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 7617 Steering Shaft: Service and Repair REMOVAL 1. Carefully pry to release the four clips and remove the steering column opening cover. NOTE: Move the shift lever to the 1 position to ease removal. 2. Pull to release the three clips and remove the fuse door. 3. Position the hood latch release handle aside. (1) Remove the screws. (2) Position the hood latch release handle aside. 4. Position the parking brake release handle aside. (1) Remove the screws. (2) Position the parking brake release handle aside. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 7618 5. Remove the instrument panel floor duct panel. - Remove two push clips and release one expander clip. 6. Remove the instrument panel steering column cover. (1) Remove the bolts. (2) Remove the lower instrument panel steering column cover. 7. Remove the steering column shaft pinch bolt. (1) Remove the steering column shaft pinch bolt. (2) Slide the intermediate shaft off at the steering column. 8. Remove the dust shield from the valve housing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 7619 9. Remove the intermediate shaft pinch bolt. 10. Slide the intermediate shaft off the steering gear input shaft. 11. Remove the intermediate shaft dash panel seal. (1) Remove the dash panel seal. (2) Remove the shaft from the vehicle. INSTALLATION 1. Install the intermediate shaft dash panel seal. (1) Install the shaft. (2) Install the dash panel seal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 7620 2. Slide the intermediate shaft on the steering gear input shaft. 3. Install the intermediate shaft pinch bolt and tighten to specification. 4. Install the dust shield to the valve housing. 5. Install the steering column shaft pinch bolt and tighten to specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 7621 6. Install the instrument panel steering column cover. (1) Position the instrument panel steering column cover. (2) Install the bolts. 7. Install the instrument panel floor duct panel. 8. Install the parking brake release handle. (1) Position the parking brake release handle. (2) Install the screws. 9. Install the hood latch release handle. (1) Position the hood latch release handle. (2) Install the screws. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 7622 10. Push to install the three clips and install the fuse door. 11. Carefully push to install the four clips and install the steering column opening cover. NOTE: Move the shift lever to the I position to ease installation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications GENERAL SPECIFICATIONS Static Steering Wheel Turning Effort ............................................................................................................................................... 2.0 Nm (18 inch lbs.) Turning Effort ................................................................................................................. ....................................................................... 2.72 Kg (6.0 lbs.) TORQUE SPECIFICATIONS Steering Wheel Bolt ............................................................................................................................. ...................................... 31-44 Nm (23-32 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 7626 Steering Wheel: Service and Repair REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN SERVICING AN AIR BAG VEHICLE AND WHEN HANDLING AN AIR BAG. - CARRY A LIVE AIR BAG WITH THE BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH A MINIMAL CHANCE OF INJURY. - PLACE A LIVE AIR BAG ON A BENCH OR OTHER SURFACE WITH THE TRIM COVER UP. - AFTER DEPLOYMENT, THE AIR BAG SURFACE MAY CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING A DEPLOYED AIR BAG. - NEVER PROBE THE CONNECTORS ON THE AIR BAGS. DOING SO MAY RESULT IN AIR BAG DEPLOYMENT WHICH COULD RESULT IN PERSONAL INJURY. - AIR BAG MODULES WITH DISCOLORED OR DAMAGED COVERS OR DEPLOYMENT DOORS MUST BE REPLACED, NOT REPAINTED. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SYSTEM IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WING PIGTAIL FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED. 1. Remove the battery cables. (1) Remove the battery ground cable. (2) Remove the battery to starter relay cable and wait one minute for the backup power supply to be depleted. NOTE: Make sure the front wheels are in the straight-ahead position. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE SERVICING OR REPLACING ANY AIR BAG SYSTEM COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY TO STARTER RELAY CABLE AND WAIT ONE MINUTE. 2. Remove the driver side air bag module. (1) Remove the two screws. (2) Disconnect the air bag sliding contact electrical connector. (3) Disconnect the horn electrical connector. (4) Remove the driver side air bag module. 3. Remove the steering wheel bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 7627 4. Use (A) 2-Jaw Puller to remove the steering wheel. CAUTION: Removing the steering wheel without using a puller can damage the column bearings. INSTALLATION 1. Install the steering wheel. (1) Position the steering wheel. (2) Install the bolt. 2. Install the driver side air bag module. (1) Connect the air bag sliding contact electrical connector. (2) Connect the horn electrical connector. (3) Position the driver side air bag module. (4) Install the two screws. 3. Connect the battery cables. (1) Connect the battery to starter relay cable. (2) Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures Tie Rod End: Technical Service Bulletins Steering - Tie Rod End Inspection Procedures Article No. 03-15-13 08/04/03 STEERING - TIE ROD END INSPECTION PROCEDURE FORD: 1997-2002 EXPEDITION 1997-2003 F-150 2001-2004 ESCAPE LINCOLN: 1998-2002 NAVIGATOR 2002-2003 BLACKWOOD This article supersedes 03-9-9 to update the vehicle models covered. ISSUE This article is to be used as an updated procedure for inspecting tie rod end wear. ACTION This procedure is designed to supplement the Workshop Manual, as it provides a more detailed tie rod end inspection procedure. SERVICE INFORMATION NOTE FOR ESCAPE VEHICLES, THIS TIE ROD END INSPECTION PROCEDURE SHOULD ONLY BE COMPLETED ON THE OUTER TIE RODS. FOR ESCAPE INNER TIE ROD INSPECTION PROCEDURES, REFER TO WORKSHOP MANUAL SECTION 211-00. Step 1 - Free Play: Check the outer tie rod ends by grasping by hand and push up and down. Check the inner tie rod ends, pushing them front to rear. If any free play is observed in a joint, it is worn and should be replaced. Step 2 - Stud Lash - Free Play: While vehicle is on the ground or on a drive-on hoist, have an assistant rotate the steering wheel rapidly back and forth from 10 o'clock to 2 o'clock to 10 o'clock while observing the inner and outer tie rods. If the outer tie rod ends have any vertical movement or the inner tie rod ends have any horizontal movement, the tie rod end with the observed movement should be replaced. Step 3 - Seal Inspection: Raise the vehicle on a hoist and remove the front wheels. The wheels will need to be turned to the right in order to inspect the passenger side inner tie rod end and to the left to inspect the drivers side inner tie rod end. Inspect all four seals for tears, perforations and wear. If there is any indication of wear or perforations on the seal, that tie rod end should be replaced. Step 4 - Stud Corrosion: For Escape Vehicles - If Squeak is noticed during Step 2, disconnect tie rod from knuckle and articulate stud in socket. If squeak is verified, replace part. While pushing down on seal, at stud end, if corrosion present at contact point at base of stud, replace part. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures > Page 7633 For All Other Vehicles Covered In This Article: Using a wrench, rotate the tie rod end so that the front of the seal on the outer tie rod end is expanded (Figure 1). Using a puffy knife or other hard, flat, dull object, lift the bottom of the seal up, exposing the stud (Figure 2). If any water escapes from the seal in the form of bubbles or in a liquid form, that tie rod end should be replaced. Closely examine the stud for signs of corrosion, especially around the interface with the knuckle. A rag might be needed to clean off any grease on the stud that impairs a good visual inspection. If there is any sign of corrosion, that tie rod end should be replaced. Rotate the tie rod end in the opposite direction to expand the inner tie rod seal. Repeat the inspection procedure used on the outer tie rod. Repeat this entire procedure on the other side of the vehicle. If there is sign of corrosion, that tie rod end should be replaced. NOTE IF ANY TIE ROD ENDS ARE REMOVED, INSPECT THE SEAL AND THE STUD AGAIN NOTING ANY DIFFERENCES IN VISUAL PERCEPTIONS FROM WHEN THE PART WAS ON THE VEHICLE. CHECKING THE STUD AFTER REMOVAL HELPS IMPROVE CONSCIOUSNESS OF ISSUES WHEN INSPECTING PARTS ON VEHICLE. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-9 WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures > Page 7634 Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 7635 Tie Rod End: Specifications TORQUE SPECIFICATIONS Outer Tie Rod End Castellated Nut ......................................................................................................................................... 77-103 Nm (56-75 ft. lbs.) Toe Set Jam Nut .......................................................................................................... ............................................................. 77-103 Nm (56-75 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner Tie Rod End: Service and Repair Inner REMOVAL 1. Remove the tire and wheel assembly. 2. Mark a reference point from the tie rod end to the front wheel spindle tie rod adjusting sleeve. 3. Remove the inner tie rod end castellated nut. (1) Remove the cotter pin. (2) Remove the castellated nut. 4. Use the Remover to separate the tie rod end. 5. Remove the tie rod end Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 7638 (1) Loosen the toe set jam nut. (2) Remove the tie rod end. - Count and record rotations. INSTALLATION 1. To install, reverse the removal procedure. 2. Inspect and adjust the toe adjustment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 7639 Tie Rod End: Service and Repair Outer REMOVAL 1. Remove the tire and wheel assembly. 2. Mark a reference point from the tie rod end to the front wheel spindle tie rod adjusting sleeve. 3. Remove the outer tie rod castellated nut. (1) Remove the cotter pin. (2) Remove the castellated nut. 4. Use Pitman Arm Puller to separate the tie rod end. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 7640 5. Remove the tie rod end. (1) Loosen the toe set jam nut. (2) Remove the tie rod end. - Count and record the rotations. INSTALLATION 1. To install, reverse the removal procedure. 2. Inspect and adjust the toe adjustment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 7641 Tie Rod End: Service and Repair Replacement REMOVAL 1. Remove the outer tie rod end. 2. Remove the front wheel spindle tie rod adjusting sleeve. (1) Loosen the toe set jam nut. (2) Remove the front wheel spindle tie rod adjusting sleeve. - Count and record the rotations. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Balljoint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.032 in (0-0.8mm) Reference Diagram ............................................................................................................................. ............................................................................. A Front Upper Balljoint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 7647 Reference Diagram ............................................................................................................................. ............................................................................. C Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 7648 Ball Joint: Specifications Ball Joint, Lower TORQUE SPECIFICATIONS Lower Ball Joint Castle Nut ................................................................................................................................................. 113-153 Nm (83-112 ft. lbs.) GENERAL SPECIFICATIONS Ball Joint Maximum Radial Play ..................................................................................................................................................... 0.794 mm (1/32 inch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 7649 Ball Joint: Specifications Ball Joint, Upper TORQUE SPECIFICATIONS Upper Ball Joint Castle Nut ..................................................................................................................................................... 77-103 Nm (57-76 ft. lbs.) GENERAL SPECIFICATIONS Maximum Radial Play .......................................................................................................................... ........................................... 0.794 mm (1/32 inch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid Ball Joint: Testing and Inspection Front Suspension Balljoint Inspection Job Aid Front Lower Balljoint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.032 in (0-0.8mm) Reference Diagram ............................................................................................................................. ............................................................................. A Front Upper Balljoint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 7652 Reference Diagram ............................................................................................................................. ............................................................................. C Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 7653 Ball Joint: Testing and Inspection Ball Joint, Lower WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. NOTE: Refer to the illustration for steps 1 and 2. 1. Raise the vehicle and place safety stands under the suspension arm axle beneath the spring. 2. Have an assistant grasp the lower and upper edge of the tire and move the wheel in and out. 3. While the wheel is being moved, observe the lower spindle arm and the lower part of the axle jaw. A 0.794 mm (1/32 inch) or greater movement between the lower portion of the suspension arm and the lower spindle arm indicates that the front suspension lower arm ball joint must be replaced. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Road test the vehicle for normal operation. 4. To check the front suspension upper ball joints, grasp the upper edge of the tire and move the wheel in and out. A 0.794 mm (1/32 inch) or greater movement between the upper spindle arm and the upper portion of the suspension arm indicates that the front suspension upper ball joint must be replaced. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 7654 Ball Joint: Testing and Inspection Ball Joint, Upper WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. NOTE: Refer to the illustration for steps 1 and 2. 1. Raise the vehicle and place safety stands under the suspension arm axle beneath the spring. 2. Have an assistant grasp the lower and upper edge of the tire and move the wheel in and out. 3. While the wheel is being moved, observe the lower spindle arm and the lower part of the axle jaw. A 0.794 mm (1/32 inch) or greater movement between the lower portion of the suspension arm and the lower spindle arm indicates that the front suspension lower arm ball joint must be replaced. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Road test the vehicle for normal operation. 4. To check the front suspension upper ball joints, grasp the upper edge of the tire and move the wheel in and out. A 0.794 mm (1/32 inch) or greater movement between the upper spindle arm and the upper portion of the suspension arm indicates that the front suspension upper ball joint must be replaced. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Specifications Control Arm: Specifications TORQUE SPECIFICATIONS Front Suspension Lower Arm Nuts .......................................................................................................................................................... 164-200 Nm (121-147 ft. lbs.) Upper Arm Nuts ............................................................................................................................................................. 113-153 Nm (83-113 ft. lbs.) Rear Suspension Lower Arm Assembly To Axle Bolt .............................................................................................................................. 128-172 Nm (94-127 ft. lbs.) Lower Arm Assembly To Frame Bolt ............................................................................................................................ 128-172 Nm (94-127 ft. lbs.) Upper Arm Assembly To Frame Bolt ............................................................................................................................ 128-172 Nm (94-127 ft. lbs.) Upper Arm Assembly To Axle Bolt ............................................................................................................................... 128-172 Nm (94-127 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower Control Arm: Service and Repair Lower REMOVAL 1. Remove the wheel hub. 2. Make preliminary adjustment references. (1) Make an alignment mark on the torsion bar and the torsion bar crossmember support. (2) Measure and record the length. 3. Relieve the torsion bar tension. (1) Remove the torsion bar adjuster bolt. (2) Install Torsion Bar Tool with Torsion Bar Tool Adapters in the B slots on Torsion Bar Tool. (3) Tighten Torsion Bar Tool until the torsion bar adjuster lifts off of the adjuster nut. (4) Remove the torsion bar adjuster nut. (5) Remove Torsion Bar Tool. (6) Remove the torsion bar adjuster. - Repeat for the other side. 4. Remove the stabilizer bar link nut from the front suspension lower arm. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7660 5. Remove the front shock absorber lower bolt and nut from the front suspension lower arm. 6. Remove the lower ball joint castellated nut. (1) Remove the lower ball joint cotter pin. (2) Remove the lower ball joint castellated nut. 7. Use Pitman Arm Puller to separate the front suspension lower arm from the front wheel knuckle. - Separate the front suspension lower arm from the front wheel knuckle. 8. Remove the front suspension lower arm. (1) Remove the two front suspension lower arm nuts. (2) Remove the two front suspension lower arm bolts. (3) Remove the front suspension lower arm and torsion bar as an assembly. 9. Separate the front suspension lower arm from the torsion bar. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7661 INSTALLATION 1. Install the front suspension lower arm. (1) Attach the front suspension lower arm to the torsion bar. (2) Install the front suspension lower arm and torsion bar as an assembly. (3) Install the front suspension lower arm bolts and nuts. 2. Install the front suspension arm lower ball joint castellated nut. (1) Position the front wheel knuckle. (2) Install the front suspension arm lower ball joint castellated nut. (3) Install a new cotter pin. 3. Install the front stabilizer bar link to the front suspension lower arm. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7662 4. Install the front shock absorber lower bolt and nut to the front suspension lower arm. 5. Load the torsion bar. (1) Install the torsion bar adjuster. (2) Install Torsion Bar Tool with Torsion Bar Tool Adapters in the B slots on the torsion bar tool. (3) Tighten Torsion Bar Tool to load the torsion bar. (4) Install the torsion bar adjuster nut. (5) Install the torsion bar adjuster bolt. (6) Remove Torsion Bar Tool. - Turn the torsion bar adjuster until the reference marks align. - Repeat for the other side. 6. Install the wheel hub. 7. Adjust the ride height. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7663 Control Arm: Service and Repair Upper REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the wheel and tire assembly. 3. Support the front suspension lower arm. - Position a jack under the front suspension lower arm. 4. Mark the position of the camber adjustment cam. 5. Safely reposition the anti-lock sensor wire. (1) Remove the bolt. (2) Safely reposition the anti-lock sensor wire. 6. Remove the upper ball joint castellated nut. (1) Remove the upper ball joint cotter pin. (2) Remove the upper ball joint castellated nut. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7664 7. Use Pitman Arm Puller to separate the front suspension upper arm from the front wheel knuckle. 8. Remove the front suspension upper arm. (1) Remove the front suspension upper arm nuts. (2) Remove the front suspension upper arm pivot bolts. (3) Remove the front suspension upper arm. INSTALLATION 1. Install the front suspension upper arm. (1) Position the front suspension upper arm. (2) Install the front suspension upper arm bolts. (3) Install the front suspension upper arm nuts. NOTE: Align the marks made during removal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7665 2. Install the front suspension arm upper ball joint castellated nut. (1) Position the front wheel knuckle. (2) Install the upper ball joint castellated nut. (3) Install a new cotter pin. 3. Position the anti-lock sensor wire. - Install the front brake anti-lock sensor wire bracket bolt. 4. Remove the jack. 5. Install the tire and wheel assembly. (1) Position the tire and wheel assembly. (2) Install the lug nuts. (3) Tighten the lug nuts in the sequence indicated. (4) Install the center cap. WARNING: WHEN THE WHEEL IS - INSTALLED, ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL THAT MAY BE PRESENT ON THE MOUNTING SURFACES OF THE WHEELS OR THE SURFACES OF THE WHEEL HUB, BRAKE DRUM OR BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUT TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. RETIGHTEN AT 800 KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7666 6. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 7. Check the front end alignment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair Rear Knuckle: Service and Repair REMOVAL 1. Remove the wheel hub. 2. Make preliminary adjustment references. (1) Make an alignment mark on the torsion bar and the torsion bar crossmember support. (2) Measure and record the length. 3. Relieve the torsion bar tension. (1) Remove the torsion bar adjuster bolt. (2) Install Torsion Bar Tool with Torsion Bar Tool Adapters in the B slots on Torsion Bar Tool. (3) Tighten the Torsion Bar Tool until the torsion bar adjuster lifts off of the adjuster nut. (4) Remove the torsion bar adjuster nut. (5) Remove Torsion Bar Tool. (6) Remove the torsion bar adjuster. 4. Safely reposition the anti-lock sensor wire. (1) Remove the bolt. (2) Safely reposition the anti-lock sensor wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7670 5. Remove the tie rod end castellated nut. (1) Remove the tie rod end cotter pin. (2) Remove the tie rod end castellated nut. 6. Use Pitman Arm Puller to separate the tie rod end. - Separate the tie rod end from the front wheel knuckle. 7. Remove the front shock absorber lower bolt and nut from the front suspension lower arm. 8. Remove the upper ball joint castellated nut. (1) Remove the upper ball joint cotter pin. (2) Remove the upper ball joint castellated nut. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7671 9. Use Pitman Arm Puller to separate the front wheel knuckle from the front suspension upper arm. 10. Remove the lower ball joint castellated nut. (1) Remove the lower ball joint cotter pin. (2) Remove the lower ball joint castellated nut. 11. Use Pitman Arm Puller to separate the front suspension lower arm from the front wheel knuckle. - Separate the front suspension lower arm from the front wheel knuckle. 12. Remove the front wheel knuckle. CAUTION: Suspend the front wheel driveshaft and joint with wire. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7672 1. Install the front suspension arm lower ball joint castellated nut. (1) Position the front wheel knuckle. (2) Install the front suspension arm lower ball joint castellated nut. (3) Install a new cotter pin. 2. Install the front suspension arm upper ball joint castellated nut. (1) Position the front wheel knuckle. (2) Install the front suspension arm upper ball joint castellated nut. (3) Install a new cotter pin. 3. Install the front shock absorber lower bolt and nut to the front suspension lower arm. 4. Install the tie rod end castellated nut. (1) Position the tie rod end. (2) Install the tie rod end castellated nut. (3) Install a new cotter pin. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7673 5. Position the anti-lock sensor wire. - Install the front brake anti-lock sensor wire bracket bolt. 6. Load the torsion bar. (1) Install the torsion bar adjuster. - Turn the torsion bar adjuster until the reference marks align. (2) Install Torsion Bar Tool with Torsion Bar Tool Adapters in the B slots on the torsion bar tool. (3) Tighten Torsion Bar Tool to load the torsion bar. (4) Install the torsion bar adjuster nut. (5) Install the torsion bar adjuster bolt. (6) Remove Torsion Bar Tool. 7. Install the wheel hub. 8. Adjust the ride height. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7674 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations Engine View The Air Suspension Solid State Compressor Relay is located near the right headlamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7679 Compressor/Pump Relay: Description and Operation The compressor relay is energized by the control module to have high current flow from the battery to the compressor motor. - A Solid State Relay is used in the air suspension system for compressor control. The relay incorporates a custom power MOSFET and ceramic hybrid circuitry. The relay switches high current loads in response to low power signals and is controlled by the logic of the control module. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7688 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7689 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: Customer Interest Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7699 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7700 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: All Technical Service Bulletins Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7705 Suspension Control Module: Locations Instrument Panel View The 4 Wheel Air-Suspension Module is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7706 Suspension Control Module: Diagrams 4 Wheel Air Suspension Module (C295) 4 Wheel Air Suspension Module (C296) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7707 Suspension Control Module: Description and Operation A microcontroller-based electronic air suspension control module controls the air compressor motor (through a solid state relay), and all system solenoids. The air suspension control module also provides power to front and rear height sensors. The air suspension control module controls vehicle height adjustments by monitoring the two height sensors, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals, and the Brake Pedal Position (BPP) switch. The air suspension control module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing of the vehicle and related components. The air suspension control module is mounted in the passenger compartment inside the instrument panel, above the radio and temperature controls. The air suspension control module is interchangeable between the RAS and 4WAS system. The air suspension control module monitors and controls the system through a 32-pin two-way connector. The air suspension control module is keyed so that it cannot be plugged into an incorrect harness. There are two sides of the harness connection to the air suspension control module. Each is uniquely colored and keyed to prevent reversing the connections. NOTE: - The 4-Wheel Air Suspension (4WAS) control module is also used for the Rear Air Suspension (RAS) system. The internal processor recognizes external circuitry to determine if it is installed in a 4WAS or a RAS system. - The air suspension control module is calibrated with information from the air suspension height sensors. A new or swapped air suspension control module requires the ride height adjustment calibration process to be performs Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7708 Suspension Control Module: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. Remove the center instrument panel finish panel. 4 3. Disconnect the transfer case rotary control switch electrical connector. 4. Remove the steering column cover trim panel. 5. Remove the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7709 6. Remove the LH instrument panel finish panel. (1) Remove the seven bolts. (2) Disconnect the electrical connector. (3) Remove the instrument panel finish panel. 7. Remove the instrument cluster panel. (1) Remove the five screws. (2) Disconnect the four electrical connectors. (3) Remove the instrument cluster panel. 8. Remove the air suspension control module screws. 9. Remove the air suspension control module. (1) Disconnect the electrical connectors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7710 (2) Remove the air suspension control module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. - The air suspension control module is calibrated with information from the ride height sensor. A new or exchanged air suspension control module requires that the ride height adjustment calibration process be performed; refer to Front Ride Height Resetting-Clear B2140 DTC. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Electrical Specifications Ride Height Sensor: Electrical Specifications GENERAL SPECIFICATIONS Rear Height Sensor Voltage ................................................................................................................ .................................................... 2.66 ± 0.02 volts Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Electrical Specifications > Page 7716 Ride Height Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Ball Stud Nut ........................................................................................................................................ .......................... 10.2-13.8 Nm (91-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front Ride Height Sensor: Locations Front Body View The Front Height Sensor is located behind the left running board. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front > Page 7719 Ride Height Sensor: Locations Rear Body View The Rear Height Sensor is located under left rear of vehicle near the axle housing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 7720 Ride Height Sensor: Description and Operation Two height sensors are mounted on the vehicle. The sensors send a voltage signal to the control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce), to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensors have a useable range of 80 mm (3 in) compared to total suspension travel of 200-250 mm (8-10 in) at the wheel. Therefore, the sensors are mounted to the suspension at a point where full suspension travel at the wheel is relative to 80 mm (3 in) of travel at the height sensor. The front height sensor upper socket is attached to the bracket to the frame at the upper control arm mounting area and the lower height sensor socket is attached to the upper control arm bracket. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace a sensor as a unit. When the height sensor indicates that the vehicle is lower than trim under normal driving conditions, the air compressor will turn on and pump compressed air to the system. When the sensor indicates that the vehicle is raised above trim under normal driving conditions, this will cause the air to be vented from the system to lower the vehicle to its trim height level. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 7721 Ride Height Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Remove the air suspension height sensor. (1) Disconnect the electrical connector. (2) Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. NOTE: - Rear height sensor shown; front similar. - The air suspension has a plastic harness retainer that must be unclipped prior to removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Description and Operation Steering Angle Sensor: Description and Operation The steering sensor is mounted inside the passenger compartment on the steering column. It provides steering rate and position to the control module through two signals. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Description and Operation > Page 7725 Steering Angle Sensor: Service and Repair REMOVAL 1. Remove the steering column. 2. Remove the shock absorber electronic steering sensor. (1) Disconnect the electrical connector. (2) Remove the screws. (3) Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. (1) Remove the steering column lower bearing spring. (2) Remove the sensor ring. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Description and Operation > Page 7726 2. Install the shock absorber electronic steering sensor. (1) Position the shock absorber electronic steering sensor. (2) Install the screws. (3) Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications TORQUE SPECIFICATIONS Bracket Mounting Bolt ................................................................................................................................................... 10.2-13.8 Nm (92-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 7730 Suspension Mode Switch: Locations The air suspension switch is located behind the RH kick panel on a mounting bracket. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 7731 Suspension Mode Switch: Description and Operation The air suspension switch is located behind the RH kick panel on a mounting bracket. The switch interrupts power to the control module. The air suspension switch supplies a signal to the control module. Without the control module receiving this signal the load leveling system is inoperative and will not react when rear of the vehicle is raised or lowered. If the air suspension is disabled by turning off air suspension switch, a "CHECK SUSP" will appear in the RH corner of the cluster with the ignition in the run position. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 7732 Suspension Mode Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 7733 5. Remove the air suspension switch bracket mounting bolt. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Bushing: > 98-15-15 > Aug > 98 > Front Suspension - Clunking Noise Stabilizer Bushing: Customer Interest Front Suspension - Clunking Noise Article No. 98-15-15 08/03/98 ^ SUSPENSION - "CLUNKING" NOISE HEARD FROM FRONT END - VEHICLES BUILT THROUGH 4/8/98 - 4X4 ONLY ^ NOISE - "CLUNKING" HEARD FROM FRONT END - VEHICLES BUILT THROUGH 4/8/98 - 4X4 ONLY LIGHT TRUCK: 1997-98 EXPEDITION 1998 NAVIGATOR This TSB article is being republished in its entirety to clarify that this article pertains to 4X4 vehicles only. ISSUE A "clunking" noise may be heard from the front end on some vehicles. This may be caused by the front stabilizer bar contacting the frame. ACTION Replace stabilizer bar and stabilizer bar insulators with revised service parts. Refer to the 1998 Expedition/Navigator Workshop Manual, Page 204-01B-21, for details. PART NUMBER PART NAME XL1Z-5482-CA Stabilizer Bar XL1Z-5484-GA Stabilizer bar insulator (2 Required) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-10-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981515A Replace Stabilizer Bar And 1.3 Hrs. Insulators DEALER CODING CONDITION BASIC PART NO. CODE 5482 33 OASIS CODES:303000, 304000, 702000, 702100, 702300 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Bushing: > 98-15-15 > Aug > 98 > Front Suspension - Clunking Noise Stabilizer Bushing: All Technical Service Bulletins Front Suspension - Clunking Noise Article No. 98-15-15 08/03/98 ^ SUSPENSION - "CLUNKING" NOISE HEARD FROM FRONT END - VEHICLES BUILT THROUGH 4/8/98 - 4X4 ONLY ^ NOISE - "CLUNKING" HEARD FROM FRONT END - VEHICLES BUILT THROUGH 4/8/98 - 4X4 ONLY LIGHT TRUCK: 1997-98 EXPEDITION 1998 NAVIGATOR This TSB article is being republished in its entirety to clarify that this article pertains to 4X4 vehicles only. ISSUE A "clunking" noise may be heard from the front end on some vehicles. This may be caused by the front stabilizer bar contacting the frame. ACTION Replace stabilizer bar and stabilizer bar insulators with revised service parts. Refer to the 1998 Expedition/Navigator Workshop Manual, Page 204-01B-21, for details. PART NUMBER PART NAME XL1Z-5482-CA Stabilizer Bar XL1Z-5484-GA Stabilizer bar insulator (2 Required) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-10-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981515A Replace Stabilizer Bar And 1.3 Hrs. Insulators DEALER CODING CONDITION BASIC PART NO. CODE 5482 33 OASIS CODES:303000, 304000, 702000, 702100, 702300 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications TORQUE SPECIFICATIONS Front Stabilizer Bar Link Bolt And Nut ........................................................................................................................................ 21-29 Nm (16-21 ft. lbs.) Rear Stabilizer Bar Link To Frame Bolt ..................................................................................................................................... 86-114 Nm (63-84 ft. lbs.) Stabilizer Bar Link To Stabilizer Bar Nut .......................................................................................................................... 86-114 Nm (63-84 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures Air Dryer: Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7756 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7757 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Specifications > Four Wheel Air Suspension Air Dryer: Specifications Four Wheel Air Suspension TORQUE SPECIFICATIONS Air Compressor Drier Hold Down Screw ................................................................................................................................... 2-3 Nm (18-27 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Specifications > Four Wheel Air Suspension > Page 7760 Air Dryer: Specifications Rear Air Suspension TORQUE SPECIFICATIONS Compressor Air Drier Hold Down Screw ........................................................................................................................... 7.6-10.4 Nm (68-88 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Specifications > Page 7761 Air Dryer: Service and Repair REMOVAL 1. Remove the air compressor. 2. Remove the drier hold down screw. 3. Turn the drier clockwise and remove it from the air compressor. NOTE: Ensure that the O-ring at the drier nose does not fall off upon removal. INSTALLATION 1. Position the air compressor drier into the air compressor and turn counterclockwise to lock the air compressor drier into place. NOTE: Ensure that the O-ring is on the compressor air drier nose upon installation for proper sealing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Specifications > Page 7762 2. Install the air compressor drier hold down screw. 3. Install the air compressor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures Air Line: Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7767 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7768 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Technical Service Bulletins > Page 7769 Air Line: Description and Operation There are six nylon air lines with quick connect air fittings in the vehicle that connect the air compressor, solenoids, air shocks, and air springs. One line connects the output of the compressor assembly to the front fill solenoid and the other line connect the output of compressor assembly to the rear fill solenoid. Another line connects the output of the rear fill solenoid to both the rear springs. The fifth air line in the front connects the output of the front fill solenoid to both the right front shock and the front gate solenoid. The last air line connects the output of the gate solenoids to the left shock. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair > Front Air Line: Service and Repair Front 1. Disconnect the air line at the air compressor drier that is connected to the front fill solenoid inlet. NOTE: If oil is present in the air lines, replace both LF and RF air shocks. Do not replace air shocks if only water is found in the air lines. 2. Disconnect the air line at the RF shock. 3. Connect NGS tester to the Data Link Connector (DLC). 4. Turn the 4WAS FRNT-FILL (front fill solenoid) solenoid ON. 5. Connect shop air line to the disconnected air line and blow out any fluid. 6. Reconnect the air line at the RF air shock. 7. Disconnect the air line at the LF air shock. 8. Turn on the following 4WAS solenoid: - FRNT_FILL (front fill solenoid) ON. - GATEVALVE (front gate solenoid) ON. 9. Connect shop air line to disconnected air line and blow out any fluid. 10. Reconnect the air line at the LF air shock. 11. Replace air compressor drier. 12. Reconnect air line to air compressor drier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair > Front > Page 7772 Air Line: Service and Repair Rear 1. Disconnect the air line at the air compressor drier that is connected to rear fill solenoid inlet. 2. Disconnect the air lines at the rear LH and RH air spring solenoids. 3. Connect NGS to the vehicle. 4. Turn the 4WAS-REAR_FILL (rear fill solenoid) solenoid ON. 5. Connect shop air line to the disconnected air line and blow out any fluid. 6. Reconnect the air line at the rear LH and RH air spring solenoids. 7. Replace air compressor drier. 8. Reconnect the air line to the air compressor drier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Specifications Air Spring: Specifications TORQUE SPECIFICATIONS Four Wheel Air Suspension Air Shock Lower Bolt ........................................................................................................................................................ 76-103 Nm (56-76 ft. lbs.) Air Shock Lower Bolt .......................................................................................................................................................... 50-60 Nm (37-44 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Description and Operation > Rear Air Spring Air Spring: Description and Operation Rear Air Spring The 4WAS vehicles use a pneumatic spring in the rear. The pneumatic spring is essentially a column of gas confined in a container, utilizing the pressure of the gas as the force medium of the spring. The ability of the gas to compress provides the desired elasticity for the spring. The air suspension system regulates the pressure in each air spring by compressing and venting system air. Increasing air pressure (compressing) raises the vehicle; decreasing air pressure (venting) lowers the vehicle. Vehicle height is maintained by the addition and removal of air in each air spring through an integral solenoid assembled to the upper spring cap and energized through the control module command. The air spring assemblies are mounted between the axle spring seats and the frame upper spring seats. The air springs replace the conventional coil springs. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Description and Operation > Rear Air Spring > Page 7778 Air Spring: Description and Operation Front Air Shock Absorbers There are different shock absorbers used for 4WAS air suspension system vehicles. 4WAS uses a conventional air shock. Enclosed in each shock absorber is an air spring. To replace a faulty shock absorber, replace the shock absorber as a unit. The air spring integrated into each air shock is capable of independently raising and lowering each corner of the vehicle based upon the pressure and volume of air supplied. The air suspension system regulates the pressure in each air shock by compressing and venting system air. Increasing air pressure (compressing) raises the vehicle and increases the total spring rate (spring effect of the air shock plus the front torsion bar) of the wheel being modified. Conversely, decreasing air pressure (venting) lowers the vehicle and effective spring rate. Vehicle height is then maintained by the addition and removal of air in each air shock. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Front Air Spring: Service and Repair Front REMOVAL 1. Deflate the air suspension. See: Service and Repair/Procedures/Inflating and Deflating the Air Suspension System 2. Raise and support the vehicle. 3. On LH air shock removal only, disconnect the top of the front height sensor from the upper frame bracket. 4. Remove the air shock lower nut and bolt. 5. Push the red ring in and hold it firmly to disconnect the air line. 6. Remove the air shock upper nut, grommet, and the air shock. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Front > Page 7781 INSTALLATION 1. To install, reverse the removal procedure. NOTE: - After installing the air shock, it is necessary to inflate the air suspension system. - When installing air line into an air shock a minimum of 3 mm (1/8 in) of white air line must be inserted into the fitting for correct installation. - Reactivate the air suspension system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Front > Page 7782 Air Spring: Service and Repair Rear REMOVAL 1. Deflate the air suspension system. See: Service and Repair/Procedures/Inflating and Deflating the Air Suspension System 2. Disconnect the battery ground cable. 3. Raise and support the vehicle. 4. Remove the rear air spring retainer. 5. Lift the bottom of the air spring off the rear axle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Front > Page 7783 6. Disconnect the air line from the air spring. - Push the green ring in and hold it firmly to release and remove the air line. 7. Disconnect the air spring solenoid electrical connector and remove the air spring. INSTALLATION 1. To install, reverse the removal procedure. NOTE: - When installing the rear air spring it is necessary to inflate the air suspension system. - When installing air line into air spring solenoid a minimum of 3 mm (1/8 in) of white air line must be inserted into the fitting for correct installation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 05-26-18 > Dec > 05 > Suspension - Air Suspension Excessive Compressor Noise Compressor/Pump: Customer Interest Suspension - Air Suspension Excessive Compressor Noise TSB 05-26-18 12/31/05 AIR SUSPENSION COMPRESSOR NOISE FORD: 1997-2004 Expedition LINCOLN: 1998-2004 Navigator This article supersedes TSB 04-5-4 to update the Service Procedure. ISSUE Some 1997-2004 Expedition and 1998-2004 Navigator vehicles equipped with air suspension, may exhibit excessive noise from the air suspension compressor. ACTION To service, replace the compressor mounting bracket with a revised bracket. Order and install Noise Kit 4L1Z-5Z205-AA. Refer to the instruction sheets included in the Kit for installation procedures. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052618A 1997-2004 1.0 Hr. Expedition/1998-2004 Navigator: Install Newly Designed Mounting Bracket And Isolators (Includes Time To Remove And Install Air Suspension Compressor) DEALER CODING CONDITION BASIC PART NO. CODE 5319 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises Compressor/Pump: Customer Interest Air Suspension - Underhood Buzzing Noises Article No. 99-2-2 02/08/99 NOISE - "BUZZING" - UNDERHOOD WHEN AIR SUSPENSION IS IN OPERATION LIGHT TRUCK: 1997-99 EXPEDITION, F-25O LD 1998-99 NAVIGATOR This TSB article is being republished in its entirety to add 1998-99 model year vehicles. ISSUE An underhood "buzzing" noise may be heard during air suspension operation. This may be caused by: ^ the air pump lines being routed too close to the front end sheet metal ^ the wheelhouse inner may be sensitive to vibration input of air suspension compressor ACTION Wrap the air lines with foam tape and place mastic applique on sheet metal under air suspension compressor. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE FOAM TAPE MUST BE PLACED ON THE AIR LINES IN A LOCATION THAT WILL PREVENT THE AIR LINES FROM CONTACTING ANY SHEET METAL. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 7796 1. Wrap the air lines with 12.7x101.6 mm (1/2x4") Foam Tape (Rotunda Squeak and Rattle Repair Kit PVC Foam Tape 164-R4901, or obtained locally) at the locations shown in Figure 1. Expedition/Navigator 4X2 and F-250 will need to be wrapped at A and B in Figure 1. Expedition/Navigator 4X4 will require tape at A, B, C, and D in Figure 1. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 7797 2. If no groundouts are found, remove air compressor and place Mastic Appliques (XL1Z-3C244-AA and XL1Z-3C245-AA) on sheet metal under air suspension compressor at A and B in Figure 2. Place appliques as follows: a. Accurately place mastic onto sheet metal in a location that will not allow the cutouts for the mounting bolt to interfere with the mounting bracket. The air suspension compressor mounting bracket and the washer bottle reservoir should have complete contact with the sheet metal, and not the mastic, at the body mounting points. CAUTION BE SURE TO WEAR PROTECTIVE GLOVES WHEN CONFORMING THE MASTIC TO PREVENT FINGER BURNS. b. Using a heat gun, uniformly heat the mastic and apply pressure to form the mastic to the sheet metal surface. PART NUMBER PART NAME (Obtain Locally) 12.7x101.6 mm (1/2x4") Foam Tape XL1Z-3C244-AA Mastic Applique (1 Of 2) XL1z-3C245-AA Mastic Applique (2 Of 2) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-7-13 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 7798 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 990202A Apply Foam Tape To 0.5 Hr. Contact Areas - 4X2 And 4X4 Models 990202B Apply Mastic Applique 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 3B484 43 OASIS CODES: 304000, 702000, 702100, 703000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 05-26-18 > Dec > 05 > Suspension - Air Suspension Excessive Compressor Noise Compressor/Pump: All Technical Service Bulletins Suspension - Air Suspension Excessive Compressor Noise TSB 05-26-18 12/31/05 AIR SUSPENSION COMPRESSOR NOISE FORD: 1997-2004 Expedition LINCOLN: 1998-2004 Navigator This article supersedes TSB 04-5-4 to update the Service Procedure. ISSUE Some 1997-2004 Expedition and 1998-2004 Navigator vehicles equipped with air suspension, may exhibit excessive noise from the air suspension compressor. ACTION To service, replace the compressor mounting bracket with a revised bracket. Order and install Noise Kit 4L1Z-5Z205-AA. Refer to the instruction sheets included in the Kit for installation procedures. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052618A 1997-2004 1.0 Hr. Expedition/1998-2004 Navigator: Install Newly Designed Mounting Bracket And Isolators (Includes Time To Remove And Install Air Suspension Compressor) DEALER CODING CONDITION BASIC PART NO. CODE 5319 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures Compressor/Pump: All Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures > Page 7808 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures > Page 7809 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises Compressor/Pump: All Technical Service Bulletins Air Suspension - Underhood Buzzing Noises Article No. 99-2-2 02/08/99 NOISE - "BUZZING" - UNDERHOOD WHEN AIR SUSPENSION IS IN OPERATION LIGHT TRUCK: 1997-99 EXPEDITION, F-25O LD 1998-99 NAVIGATOR This TSB article is being republished in its entirety to add 1998-99 model year vehicles. ISSUE An underhood "buzzing" noise may be heard during air suspension operation. This may be caused by: ^ the air pump lines being routed too close to the front end sheet metal ^ the wheelhouse inner may be sensitive to vibration input of air suspension compressor ACTION Wrap the air lines with foam tape and place mastic applique on sheet metal under air suspension compressor. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE FOAM TAPE MUST BE PLACED ON THE AIR LINES IN A LOCATION THAT WILL PREVENT THE AIR LINES FROM CONTACTING ANY SHEET METAL. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 7814 1. Wrap the air lines with 12.7x101.6 mm (1/2x4") Foam Tape (Rotunda Squeak and Rattle Repair Kit PVC Foam Tape 164-R4901, or obtained locally) at the locations shown in Figure 1. Expedition/Navigator 4X2 and F-250 will need to be wrapped at A and B in Figure 1. Expedition/Navigator 4X4 will require tape at A, B, C, and D in Figure 1. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 7815 2. If no groundouts are found, remove air compressor and place Mastic Appliques (XL1Z-3C244-AA and XL1Z-3C245-AA) on sheet metal under air suspension compressor at A and B in Figure 2. Place appliques as follows: a. Accurately place mastic onto sheet metal in a location that will not allow the cutouts for the mounting bolt to interfere with the mounting bracket. The air suspension compressor mounting bracket and the washer bottle reservoir should have complete contact with the sheet metal, and not the mastic, at the body mounting points. CAUTION BE SURE TO WEAR PROTECTIVE GLOVES WHEN CONFORMING THE MASTIC TO PREVENT FINGER BURNS. b. Using a heat gun, uniformly heat the mastic and apply pressure to form the mastic to the sheet metal surface. PART NUMBER PART NAME (Obtain Locally) 12.7x101.6 mm (1/2x4") Foam Tape XL1Z-3C244-AA Mastic Applique (1 Of 2) XL1z-3C245-AA Mastic Applique (2 Of 2) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-7-13 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 7816 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 990202A Apply Foam Tape To 0.5 Hr. Contact Areas - 4X2 And 4X4 Models 990202B Apply Mastic Applique 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 3B484 43 OASIS CODES: 304000, 702000, 702100, 703000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures Compressor/Pump: All Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures > Page 7822 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures > Page 7823 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Page 7824 Compressor/Pump: Specifications TORQUE SPECIFICATIONS Air Compressor Bracket Bolts ............................................................................................................................................ 7.6-10.4 Nm (68-88 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Page 7825 Compressor/Pump: Description and Operation The air compressor: - Is not interchangeable with the Rear Air Suspension (RAS) air compressor. - Consists of the compressor and vent solenoid; neither are replaceable as individual items. - Is mounted in the engine compartment between the washer fluid bottle and headlamp (RH front corner). - Is a single cylinder electric motor driven unit that provides pressurized air as required. - Is powered by a solid state relay, controlled by the air suspension control module. - Passes pressurized air through the compressor air drier that contains silica gel (a drying agent). Moisture is then removed from the compressor air drier when vented air passes out of the system during vent operation. - The compressor air drier may be replaced separately. - Incorporates a snorkel that may be replaced separately. - The compressor air drier has dual ports and is not interchangeable with the RAS drier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Page 7826 Compressor/Pump: Service and Repair REMOVAL 1. Deflate the air suspension system. 2. Disconnect the battery ground cable. 3. Remove the windshield washer pump and reservoir. 4. Disconnect the air lines from the air compressor. (1) Depress the red plastic retaining rings and hold firmly while pulling out on the air lines. (2) Disconnect the air lines. 5. Disconnect the air compressor electrical connector. 6. Remove the air compressor bracket bolts and remove the air compressor and drier assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Page 7827 INSTALLATION 1. To install, reverse the removal procedure. NOTE: - When reinstalling air lines into compressor drier a maximum of 3 mm (1/8 in) of visible white air line must be installed for correct installation. - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. - After installing the air compressor it is necessary to inflate the air suspension system. See: Service and Repair/Procedures/Inflating and Deflating the Air Suspension System Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations Engine View The Air Suspension Solid State Compressor Relay is located near the right headlamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7831 Compressor/Pump Relay: Description and Operation The compressor relay is energized by the control module to have high current flow from the battery to the compressor motor. - A Solid State Relay is used in the air suspension system for compressor control. The relay incorporates a custom power MOSFET and ceramic hybrid circuitry. The relay switches high current loads in response to low power signals and is controlled by the logic of the control module. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Diagnostic Connector, Suspension > Component Information > Description and Operation Diagnostic Connector: Description and Operation The air suspension diagnostic connector is used to aid the technician in diagnosing the air suspension system. It is also used to vent the system of compressed air when air suspension system components need to be repaired or replaced. The air suspension diagnostic connector is located under steering column. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures Level Control Solenoid Valve: Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7839 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7840 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Description and Operation > Electronic Level Control Solenoid Valve Level Control Solenoid Valve: Description and Operation Electronic Level Control Solenoid Valve The air spring solenoid valve: - Allows air to enter and exit the air spring during leveling operations. - Is electrically operated and controlled by the control module. - Is only replaced as a unit. WARNING: NEVER ROTATE AN AIR SPRING SOLENOID VALVE TO THE RELEASE SLOT IN THE END CAP FITTING UNTIL ALL PRESSURIZED AIR HAS ESCAPED FROM THE SPRING TO PREVENT DAMAGE OR INJURY. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Description and Operation > Electronic Level Control Solenoid Valve > Page 7843 Level Control Solenoid Valve: Description and Operation Exhaust Solenoid (Level Control) The Pressure Relief Valve (PRV) protects the rear air suspension components by venting the system to a specific pressure in the case of a system malfunction. The system will decrease the pressure to an acceptable level to maintain vehicle height. In the normal operation mode with normal system pressure the PRV is constantly closed and does not have any effect on the system performance or function. The PRV is replaceable without any air lines. The PRV is located in the rear of the vehicle on the middle of crossmember #5 as a part of the rear air line assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Description and Operation > Electronic Level Control Solenoid Valve > Page 7844 Level Control Solenoid Valve: Description and Operation Inflator Solenoid, Level Control Front Fill Solenoid The front fill solenoid connects the output of the compressor assembly to the two front air shocks. When energized along with the front gate solenoid, air pressure to the front axle can be modified, affecting its height relative to the body. Front Gate Solenoid The front gate solenoid provides pneumatic isolation of the left and right sides of the vehicle. The separation is necessary to eliminate the transfer of air from left to right front air shocks during roll conditions. When the solenoids are off (closed) the left and right air shocks are separated, allowing a pressure differential to be generated. In a turn, the increased pressure in the two outermost air shocks raises the two outer wheel spring rates, decreasing vehicle roll. Conversely, opening (energizing) the gate solenoid on smooth driving surfaces connects the left and right air shocks. This forces left and right side air pressures to be the same. Also, allowing the transfer of air reduces the resistance to vertical wheel movement, resulting in a softer ride. Rear Fill Solenoid The rear fill solenoid connects the output of the compressor assembly to the two rear air shocks. When energized along with the two integrated rear solenoids, air pressure to the rear axle can be modified, affecting its height relative to the body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Description and Operation > Electronic Level Control Solenoid Valve > Page 7845 Level Control Solenoid Valve: Description and Operation Vent Solenoid (Level Control) The vent solenoid: - Allows air to escape from the system during venting actions. - Is located in the air compressor cylinder head. - Shares a common electrical connector with the air compressor motor. - Is enclosed in the cylinder head casting, which forms an integral valve housing that allows the valve tip to enter the pressurized side of the system. - Has an O-ring seal that prevents air leakage past the valve tip. - Opens when the air suspension control module determines lowering is required. - Provides an escape route for pressurized air when system pressures exceed safe operating levels. - Has a 260 psi internal relief valve. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Electronic Level Control Solenoid Valve Level Control Solenoid Valve: Service and Repair Electronic Level Control Solenoid Valve Functional REMOVAL 1. Remove the air spring assembly. 2. Remove the air spring solenoid clip. CAUTION: Remove any dirt or other debris from the air spring assembly prior to removing to air spring solenoid from the air spring assembly. 3. Twist air spring solenoid and remove. NOTE: Inspect solenoid O-rings and replace as necessary. INSTALLATION 1. To install, reverse the removal procedure. Non-Functional REMOVAL WARNING: DO NOT REMOVE AN AIR SPRING UNDER ANY CIRCUMSTANCES WHEN THERE IS PRESSURE IN THE AIR SPRING. DO NOT REMOVE ANY COMPONENTS SUPPORTING AN AIR SPRING WITHOUT EITHER EXHAUSTING THE AIR OR PROVIDING SUPPORT FOR THE AIR SPRING TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. NOTE: The air spring solenoid has a two-stage pressure relief fitting similar to a radiator cap. 1. Raise and support the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Electronic Level Control Solenoid Valve > Page 7848 2. Disconnect the air spring solenoid electrical connector. 3. Disconnect the air line from the air spring. - Push the green ring in and hold firmly to release and remove the air line. 4. Remove the air spring solenoid clip. CAUTION: Remove any dirt or other debris from the air spring prior to removing the air spring solenoid from the air spring. 5. Rotate the air spring solenoid out of the air spring to the first detent to release the air from the air spring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Electronic Level Control Solenoid Valve > Page 7849 6. Remove the air spring retainer. 7. Lift the bottom of the air spring from the rear axle and remove the air spring. 8. Twist air spring solenoid and remove. NOTE: Inspect air spring solenoid O-rings and replace as necessary. INSTALLATION 1. To install, reverse removal procedure. NOTE: - Be sure the new air spring solenoid is fully seated into both stages of the air spring. - After installing the solenoid it is necessary to inflate the air suspension system. See: Service and Repair/Procedures/Inflating and Deflating Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Electronic Level Control Solenoid Valve > Page 7850 the Air Suspension System - When installing air line into the solenoid a minimum of 3 mm (1/8 in) of white air line must be inserted into the fitting for correct installation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Electronic Level Control Solenoid Valve > Page 7851 Level Control Solenoid Valve: Service and Repair Inflator Solenoid, Level Control REMOVAL 1. Deflate the air suspension system. See: Service and Repair/Procedures/Inflating and Deflating the Air Suspension System 2. Disconnect the battery ground cable. 3. Raise and support the vehicle. 4. Disconnect the electrical connector. NOTE: Front fill solenoid shown, front gate solenoid and rear fill solenoid similar. 5. Push in the red rings and disconnect the air lines. 6. Remove the solenoid from the frame. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Electronic Level Control Solenoid Valve > Page 7852 NOTE: Rear fill solenoid shown, front gate solenoid and front fill solenoid similar. INSTALLATION 1. To install reverse removal procedure. NOTE: - After installing the solenoid it is necessary to inflate the air suspension system. - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. - When installing air line into solenoid a minimum of 3 mm (1/8 in) of white air line must be inserted into the fitting for correct installation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Specifications > Electrical Specifications Ride Height Sensor: Electrical Specifications GENERAL SPECIFICATIONS Rear Height Sensor Voltage ................................................................................................................ .................................................... 2.66 ± 0.02 volts Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Specifications > Electrical Specifications > Page 7857 Ride Height Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Ball Stud Nut ........................................................................................................................................ .......................... 10.2-13.8 Nm (91-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Locations > Front Ride Height Sensor: Locations Front Body View The Front Height Sensor is located behind the left running board. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Locations > Front > Page 7860 Ride Height Sensor: Locations Rear Body View The Rear Height Sensor is located under left rear of vehicle near the axle housing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 7861 Ride Height Sensor: Description and Operation Two height sensors are mounted on the vehicle. The sensors send a voltage signal to the control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce), to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensors have a useable range of 80 mm (3 in) compared to total suspension travel of 200-250 mm (8-10 in) at the wheel. Therefore, the sensors are mounted to the suspension at a point where full suspension travel at the wheel is relative to 80 mm (3 in) of travel at the height sensor. The front height sensor upper socket is attached to the bracket to the frame at the upper control arm mounting area and the lower height sensor socket is attached to the upper control arm bracket. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace a sensor as a unit. When the height sensor indicates that the vehicle is lower than trim under normal driving conditions, the air compressor will turn on and pump compressed air to the system. When the sensor indicates that the vehicle is raised above trim under normal driving conditions, this will cause the air to be vented from the system to lower the vehicle to its trim height level. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 7862 Ride Height Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Remove the air suspension height sensor. (1) Disconnect the electrical connector. (2) Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. NOTE: - Rear height sensor shown; front similar. - The air suspension has a plastic harness retainer that must be unclipped prior to removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7871 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7872 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: Customer Interest Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7882 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7883 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: All Technical Service Bulletins Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7888 Suspension Control Module: Locations Instrument Panel View The 4 Wheel Air-Suspension Module is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7889 Suspension Control Module: Diagrams 4 Wheel Air Suspension Module (C295) 4 Wheel Air Suspension Module (C296) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7890 Suspension Control Module: Description and Operation A microcontroller-based electronic air suspension control module controls the air compressor motor (through a solid state relay), and all system solenoids. The air suspension control module also provides power to front and rear height sensors. The air suspension control module controls vehicle height adjustments by monitoring the two height sensors, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals, and the Brake Pedal Position (BPP) switch. The air suspension control module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing of the vehicle and related components. The air suspension control module is mounted in the passenger compartment inside the instrument panel, above the radio and temperature controls. The air suspension control module is interchangeable between the RAS and 4WAS system. The air suspension control module monitors and controls the system through a 32-pin two-way connector. The air suspension control module is keyed so that it cannot be plugged into an incorrect harness. There are two sides of the harness connection to the air suspension control module. Each is uniquely colored and keyed to prevent reversing the connections. NOTE: - The 4-Wheel Air Suspension (4WAS) control module is also used for the Rear Air Suspension (RAS) system. The internal processor recognizes external circuitry to determine if it is installed in a 4WAS or a RAS system. - The air suspension control module is calibrated with information from the air suspension height sensors. A new or swapped air suspension control module requires the ride height adjustment calibration process to be performs Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7891 Suspension Control Module: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. Remove the center instrument panel finish panel. 4 3. Disconnect the transfer case rotary control switch electrical connector. 4. Remove the steering column cover trim panel. 5. Remove the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7892 6. Remove the LH instrument panel finish panel. (1) Remove the seven bolts. (2) Disconnect the electrical connector. (3) Remove the instrument panel finish panel. 7. Remove the instrument cluster panel. (1) Remove the five screws. (2) Disconnect the four electrical connectors. (3) Remove the instrument cluster panel. 8. Remove the air suspension control module screws. 9. Remove the air suspension control module. (1) Disconnect the electrical connectors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7893 (2) Remove the air suspension control module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. - The air suspension control module is calibrated with information from the ride height sensor. A new or exchanged air suspension control module requires that the ride height adjustment calibration process be performed; refer to Front Ride Height Resetting-Clear B2140 DTC. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications TORQUE SPECIFICATIONS Bracket Mounting Bolt ................................................................................................................................................... 10.2-13.8 Nm (92-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Specifications > Page 7897 Suspension Mode Switch: Locations The air suspension switch is located behind the RH kick panel on a mounting bracket. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Specifications > Page 7898 Suspension Mode Switch: Description and Operation The air suspension switch is located behind the RH kick panel on a mounting bracket. The switch interrupts power to the control module. The air suspension switch supplies a signal to the control module. Without the control module receiving this signal the load leveling system is inoperative and will not react when rear of the vehicle is raised or lowered. If the air suspension is disabled by turning off air suspension switch, a "CHECK SUSP" will appear in the RH corner of the cluster with the ignition in the run position. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Specifications > Page 7899 Suspension Mode Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Specifications > Page 7900 5. Remove the air suspension switch bracket mounting bolt. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal Suspension Spring ( Coil / Leaf ): Service and Repair Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the driveshaft. 4. Disconnect the rear brake anti-lock sensor (ABS) electrical connector. 5. Relieve the tension on the parking brake system. (1) Pull the front parking brake cable and conduit. (2) Insert a suitable retainer into the parking brake control NOTE: Make sure the parking brake control is fully released. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 7905 6. Disconnect the rear parking brake cable and conduit from the rear axle. (1) Remove the rear parking brake cable and conduit from the rear axle bracket assembly. (2) Remove the cable from the caliper. - Repeat for other side. 7. Position the disc brake caliper aside. (1) Remove the bolts. (2) Secure the caliper aside with wire. - Repeat for other side. 8. Disconnect the axle vent tube. 9. Disconnect the stabilizer bar from the rear axle. (1) Remove the bolts from each stabilizer bar retainer. (2) Remove the retainers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 7906 10. Use Hi-Lift Jack to support the rear axle. 11. Remove the lower shock absorber nut and bolt. - Repeat for other side. 12. Remove the rear axle to trackbar assembly bolt. 13. Remove the rear suspension lower arm assembly to the axle bolt. - Repeat for other side. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 7907 14. Remove the rear suspension upper arm assembly to the rear axle bolt. - Repeat for other side. 15. Lower the rear axle and remove the coil spring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 7908 Suspension Spring ( Coil / Leaf ): Service and Repair Installation NOTE: Do not tighten any nuts or bolts until the rear suspension is raised so that the rear suspension lower arms are parallel to the ground. Once in position, tighten all the nuts and bolts to specification. 1. Install the rear coil spring. 2. Position the rear suspension upper arm assemblies to the axle and install the bolts. 3. Position the rear suspension lower arm assemblies to the axle and install the bolts. 4. Position the trackbar assembly to the axle and install the bolts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 7909 5. Position the shock absorbers to the axle and install the bolts. 6. Position the stabilizer bar to the axle and install the stabilizer bar retainers and bolts. 7. Position the disc brake caliper. (1) Position caliper. (2) Install the bolts. 8. Connect parking brake cables and conduit to the axle. (1) Install the cable and conduit to the lever. (2) Install the cable and conduit to rear axle bracket assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 7910 9. Install the tire and wheel assembly. (1) Position the tire and wheel assembly. (2) Install the lug nuts and lower the vehicle. (3) Tighten the lug nuts in sequence. (4) Install the wheel cover. 10. Remove the pin from parking brake control assembly. 11. Connect the rear brake anti-Lock sensor (ABS) electrical connector. 12. Connect the axle vent tube. 13. Install the driveshaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications Suspension Strut / Shock Absorber: Specifications TORQUE SPECIFICATIONS Front Shock Lower Bolt And Nut ................................................................................................................................................ 77-103 Nm (57-76 ft. lbs.) Shock Upper Nut ................................................................................................... ............................................................... 30-40 Nm (22-29 ft. lbs.) Rear Shock Absorber To Axle Nut ............................................................................................................................................. 86-114 Nm (63-84 ft. lbs.) Shock Absorber To Frame Nut .......................................................................................................................................... 86-114 Nm (63-84 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Suspension Strut / Shock Absorber: Initial Inspection and Diagnostic Overview CAUTION: The low pressure gas shock absorbers are charged with nitrogen gas to 931 kPa (135 psi) for 1-3/16 inch bore, and 1034 kPa (150 psi) for 1-3/8 inch bore. Do not attempt to open, puncture, or apply heat to the shock absorbers. All vehicles are equipped with low pressure gas-filled hydraulic shock absorbers of the direct acting type. They are non-adjustable and non-refillable. They cannot be serviced as cartridges and must be serviced as shock assemblies. Before replacing a shock absorber, check the action of the shock absorbers as follows. 1. Check all tires for proper inflation pressure. 2. Check tire condition to confirm proper front end alignment, tire balance and overall tire condition such as separation or bulges. 3. Check the vehicle for optional suspension equipment such as heavy-duty handling or trailer tow suspensions. These suspensions will have a firmer feeling ride than standard suspensions. 4. Check the vehicle attitude for evidence of possible overload or sagging. Many times, front springs and front shock absorbers are replaced in an effort to solve a vehicle sag concern. Shock absorbers are, by design, hydraulic damping units only and unlike suspension springs, do not support any suspension loads. Therefore, replacing a shock absorber will not correct a vehicle sag concern. 5. Road test the vehicle to confirm the customer concern. 6. Make sure the shock absorber is securely and properly installed. 7. Check the shock absorber insulators for damage and wear. Replace any worn or damaged insulators and tighten attachments to the specified torque (on a shock absorber which incorporates internal insulators, replace the shock absorbers). 10. Inspect the shock absorber for evidence of fluid leakage. Leakage is a condition in which the entire shock body is covered with oil, and the oil will drip from the shock onto the pavement. A light film of oil (weepage) on the upper portion of the front shock absorber is permissible and is a result of proper shock lubrication. Weepage is a condition in which a thin film of oil may be deposited on the shock outer tube (body) and is normally noticed due to the collection of dust in this area. Front shock absorbers which exhibit this weepage condition are functional units and should not be replaced. 11. If leakage exists: - Make sure the fluid observed is not from sources other than the front shock absorber. - Replace the worn or damaged front shock absorber. 12. Disconnect the lower end of the shock absorber. 13. Extend and compress the shock absorber as fast as possible, using as much travel as possible. Action should become smooth and uniform throughout each stroke. Higher resistance on extension than on compression is a normal condition. - Faint swish noises are also normal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7916 Suspension Strut / Shock Absorber: Component Tests and General Diagnostics Bench Test The front shock absorbers are gas-pressurized, which results in their being fully extended when not restrained. If a front shock absorber does not fully extend, it is damaged and should be replaced. With the front shock absorber in the normal upright position, compress it and allow it to extend three times to purge the pressure chamber of any gas that may have been introduced during handling. Place the front shock absorber right side up in a vise. Hand-stroke the front shock absorber as fast as possible using as much travel as possible. Action should be smooth and uniform throughout each stroke. Higher resistance on extension than on compression is normal. The following conditions are abnormal: - A lag or skip at a reversal of travel near mid-stroke when the front shock absorber is properly primed and in the installed position. - Seizing. - Noise, other than a faint swish, such as a clicking upon fast stroke reversal. - Excessive fluid leakage. - With rod fully extended, any lateral motion of rod in relation to outer cylinder. If front shock absorber action remains erratic after purging air, install a front shock absorber, replacing only the damaged front shock absorber. Front shock absorbers do not need to be replaced in pairs. Hoist Check WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Noise: Check for loose/damaged suspension or shock attachments when locating a noise symptom. Verify that all the attachments or the suspension components and the front springs and front shock absorbers are in good condition and tight. Replace any worn or damaged parts or components. 2. Bottom/Hopping: Check the condition of the rubber suspension travel stops (front suspension bumpers). Examine them for evidence of previous overload or damaged components; replace them if they are worn or missing. 3. Force-Check: Support the front axle and remove the lower front shock attachment. Stroke the front shock body using as much travel as possible. The action should be smooth and uniform throughout each stroke. Damping forces should be equivalent on both sides of the vehicle. 4. Replace only the worn or damaged front shock absorber. In the past, it was recommended that front shock absorbers be replaced in pairs if one unit became unserviceable. Improved sealing, new materials, design, and improved rod machining and hardening techniques have added to the reliability of shock absorbers. Therefore, front shock absorbers no longer need to be replaced in pairs when only one unit is not serviceable. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber Suspension Strut / Shock Absorber: Service and Repair Front Air Shock Absorber Air Shock Absorber Removal and Installation NOTE: The vehicle must be positioned on a suitable lifting device prior to deflating the air suspension switch. 1. Deflate the air suspension system. 2. Raise and support the vehicle. Front Air Shock Absorber 3. On LH air shock removal only, disconnect the top of the front height sensor from the upper frame bracket. 4. Remove the air shock lower nut and bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 7919 5. Disconnect the air spring solenoid air line. - Compress the quick connect locking ring and pull out the air line. 6. Remove the air shock upper nut, grommet and the air shock. 7. NOTE: After installing the air shock, it is necessary to inflate the air suspension system. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 7920 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 7921 Suspension Strut / Shock Absorber: Service and Repair Rear REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the tire and wheel assembly. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. 3. Use Hi-Lift Jack to support the rear axle. 4. Remove the upper shock absorber nut and bolt. 5. Remove the lower shock absorber nut, bolt and the shock absorber. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 7922 1. To install reverse the removal procedure. WARNING: ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL PRESENT ON THE MOUNTING SURFACES OF THE WHEEL OR THE SURFACE OF THE WHEEL HUB, BRAKE DRUM OR FRONT DISC BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL TO METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUTS TO LOOSEN AND COULD ALLOW THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. NOTE: Tighten the lug nuts in the sequence indicated. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 7923 Suspension Strut / Shock Absorber: Service and Repair Front Shock Absorber REMOVAL 1. Hold the shock absorber stem and remove the upper front shock absorber nut, and washer assembly. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Raise and support the vehicle. 3. Remove the shock absorber. (1) Remove the lower nut and bolt. (2) Remove the shock absorber. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 7924 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications Suspension Travel Bumper: Specifications TORQUE SPECIFICATIONS Axle Bumper Bolt ................................................................................................................................. ..................................... 34-46 Nm (26-34 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications Torsion Bar: Specifications TORQUE SPECIFICATIONS Torsion Bar Crossmember Support Bolts .................................................................................................................................. 40-54 Nm (29-40 ft. lbs.) Torsion Bar Crossmember Support Nuts ................................................................................................................................... 53-72 Nm (39-53 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 7931 Torsion Bar: Service and Repair REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Make preliminary adjustment references. (1) Make an alignment mark on the torsion bar and the torsion bar crossmember support. (2) Measure and record the length. 3. Relieve the torsion bar tension. (1) Remove the torsion bar adjuster bolt. (2) Install Torsion Bar Tool with Torsion Bar Tool Adapters in the B slots on Torsion Bar Tool. (3) Tighten Torsion Bar Tool until the torsion bar adjuster lifts off of the adjuster nut. (4) Remove the torsion bar adjuster nut. (5) Remove Torsion Bar Tool. (6) Remove the torsion bar adjuster. 4. Remove the torsion bars. (1) Remove the torsion bar crossmember support bolts and nuts. (2) Remove the torsion bar crossmember support. (3) Remove the torsion bars. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 7932 1. Install the torsion bar. (1) Position the torsion bars. (2) Position the torsion bar crossmember support. (3) Install the torsion bar crossmember support bolts and nuts. 2. Load the torsion bar. (1) Install the torsion bar adjuster. (2) Install Torsion Bar Tool with torsion Bar Tool Adapters in the B slots on the torsion bar tool. (3) Tighten Torsion Bar Tool to load the torsion bar. (4) Install the torsion bar adjuster nut. (5) Install the torsion bar adjuster bolt. (6) Remove Torsion Bar Tool. 3. Adjust the ride height. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications Trailing Arm: Specifications TORQUE SPECIFICATIONS Trackbar To Rear Axle Bolt .............................................................................................................................................. 170-230 Nm (125-170 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 7936 Trailing Arm: Service and Repair REMOVAL 1. Raise and support the vehicle. 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. 2. Remove the air suspension height sensor, if so equipped. (1) Disconnect the electrical connector. (2) Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. NOTE: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. 3. Remove the RH trackbar bolt. 4. Remove the LH trackbar nut and bolt. 5. Remove the trackbar from the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 7937 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7942 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7943 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7944 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7945 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7946 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7947 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7948 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7949 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7950 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7951 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7952 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7953 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7954 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7955 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7956 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7957 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7958 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7959 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7960 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7961 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7962 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7963 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7964 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7965 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7966 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7967 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7968 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7969 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7970 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7971 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7972 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7973 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7974 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7975 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7976 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7977 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7978 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7979 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7980 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7981 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7982 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7983 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7984 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7985 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7986 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7987 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7988 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7989 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7990 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7991 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7992 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7993 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7994 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7995 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7996 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7997 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7998 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7999 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8001 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8002 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8003 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8004 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8005 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8006 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8007 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8008 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8009 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8010 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8011 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8012 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8013 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8014 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8015 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8016 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8017 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8018 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8019 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8020 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8021 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8022 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8023 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8024 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8025 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8026 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8027 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8028 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8029 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8030 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8031 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8032 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8033 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8034 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 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. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8035 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 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. 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 the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8036 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Page 8037 Wheel Bearing: Specifications Rear Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front REMOVAL NOTE: The wheel bearing and hub are replaced as an assembly. 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the wheel and tire assembly. 3. Remove the front disc brake rotor. 4. Remove the front wheel hub nut. (1) Remove the cotter pin. (2) Remove the retainer. (3) Remove the nut. 5. Remove the front disc brake rotor shield. (1) Remove the bolts. (2) Remove the front disc brake rotor shield. 6. Remove the front brake anti-lock sensor. (1) Remove the bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 8040 (2) Remove the front brake anti-lock sensor. 7. Remove the wheel hub. (1) Remove the bolts. (2) Push the CV joint inboard. Remove the wheel hub. CAUTION: Do not over extend CV joint and boots when removing the hub and bearing assembly. NOTE: The CV joint is a slip fit into the wheel hub and bearing. A puller will not normally be required. 8. Remove the seal. INSTALLATION 1. Install the seal. - Use Knuckle Seal Replacer, Threaded Drawbar and Bearing Cup Replacer to install the seal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 8041 2. Install the wheel hub. (1) Position the wheel hub on the front wheel driveshaft and joint and into the front wheel knuckle. (2) Install the bolts. 3. Install the front brake anti-lock sensor. (1) Install the front brake anti-lock sensor into the wheel hub. (2) Install the bolt. 4. Install the front disc brake rotor shield and front axle hub nut. (1) Position the front disc brake rotor shield. (2) Install the bolts. (3) Install the front axle hub nut. (4) Install the retainer. (5) Install cotter pin. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 8042 5. Install the front disc brake rotor. 6. Install the tire and wheel assembly. (1) Position the tire and wheel assembly. (2) Install the lug nuts. (3) Tighten the lug nuts in the sequence indicated. (4) Install the center cap. WARNING: WHEN THE WHEEL IS INSTALLED, ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL THAT MAY BE PRESENT ON THE MOUNTING SURFACES OF THE WHEELS OR THE SURFACES OF THE WHEEL HUB, BRAKE DRUM OR BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUT TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. RETIGHTEN AT 800 KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. 7. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 8043 Wheel Bearing: Service and Repair Rear 8.8 Inch Ring Gear Special Tools Special Tools REMOVAL 1. Remove the axle shaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 8044 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with debris. Use Impact Slide Hammer and Axle Wheel Bearing Puller to remove the rear wheel bearing and inner wheel bearing oil seal. INSTALLATION 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2Cl92-A. 2. Use Axle Wheel Bearing Replacer with Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-l-C or equivalent meeting Ford specification ESA-MlC75-B. 4. Use Axle Seal Replacer with Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shafts. 9.75 Inch Ring Gear Models With Rear Disc Brakes Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 8045 Special Tools REMOVAL 1. Remove the axle shaft. 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with debris. Use the Impact Slide Hammer and the Axle Bearing Remover to remove the rear wheel bearing and inner wheel bearing oil seal. INSTALLATION 1. Lubricate the new rear axle bearing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 8046 - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use the Axle Wheel Bearing Replacer with the Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Use the Axle Seal Replacer with the Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Hub Nut 255-345 Nm (188-254 ft.lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation WARNING: ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. Jacking Points - Front, 4x4 The jacking point is a raised boss located on the front suspension lower arm. Jacking Points - Front, 4x2 The jacking point is a bracket welded to the frame located behind the front tire and wheel assembly. Jacking Points - Rear CAUTION: Never use the differential housing as a lifting point. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 8055 The rear jacking points are located on the rear axle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Lifting Vehicle Lifting: Service and Repair Lifting WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Lifting Points-Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Lifting Points - Drive On Hoist The vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Lifting > Page 8058 Vehicle Lifting: Service and Repair Lifting, Jacking and Hoisting WARNING: ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. Jacking Points - Front, 4x4 The jacking point is a raised boss located on the front suspension lower arm. Jacking Points - Front, 4x2 The jacking point is a bracket welded to the frame located behind the front tire and wheel assembly. Jacking Points - Rear Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Lifting > Page 8059 CAUTION: Never use the differential housing as a lifting point. The rear jacking points are located on the rear axle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Lifting > Page 8060 Vehicle Lifting: Service and Repair Vehicle Lifting and Jacking WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Lifting Points-Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Lifting Points - Drive On Hoist The vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications Spare Tire: Specifications TORQUE SPECIFICATIONS Spare Tire Carrier Bolts ............................................................................................................................................................. 23-32 Nm (17-23 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications > Page 8065 Spare Tire: Service and Repair REMOVAL 1. Lower the spare tire. (1) Insert the drive end of the jack handle through the opening left of the license plate. (2) Turn the jack handle until slack is present in the cable. 2. Remove the spare tire. (1) Slide the retainer through the center of the spare tire assembly. (2) Remove the spare tire assembly. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Remove the spare tire carrier. (1) Remove the two bolts. (2) Turn the spare tire carrier to disengage the spare tire carrier from the tabs and remove the spare tire carrier. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications > Page 8066 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8071 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8072 Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8073 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8074 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8075 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8076 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8077 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8078 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8079 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8080 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8081 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8082 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8083 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8084 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8085 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8086 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8087 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8088 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8089 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8090 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8091 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8092 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8093 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8094 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8095 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8096 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8097 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8098 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8099 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8100 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8101 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8102 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8103 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8104 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8105 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8106 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8107 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8108 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8109 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8110 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8111 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8112 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8113 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8114 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8115 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8116 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8117 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8118 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8119 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8120 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8121 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8122 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8123 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8124 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8125 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8126 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8127 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8128 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8129 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8130 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8131 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8132 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8133 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8134 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8135 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8136 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8137 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8138 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8139 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8140 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8141 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8142 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8143 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8144 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8145 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8146 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8147 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8148 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8149 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8150 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8151 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8152 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8153 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8154 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8155 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8156 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8157 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8158 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8159 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8160 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8161 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8162 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8163 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8164 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8165 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 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. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8166 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 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. 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 the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8167 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 8168 Wheels: Specifications GENERAL SPECIFICATIONS Cast Aluminum .................................................................................................................................... ................................................................ 17 x 7.5J Steel .................................................................... .................................................................................................................................................... 16 x 7J Styled Aluminum ............................................................................................................................. ....................................................................... 16 x 7J Styled Argent Steel ......................................... ........................................................................................................................................................ 16 x 7J Wheel Offset ................................................................................................................................ ........................................................................... 14 mm Wheel Rim Runout (Radial Or Lateral) ........................................................................................................................................... 1.12 mm (0.044 inch) Maximum Balance Weight [a] .......................................................................................... ............................................................................. 170 g (6 oz.) [a] Total Of Inner And Outer Wheel Flanges Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service Precautions > Technician Safety Information Wheels: Technician Safety Information WARNING: NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, FOR EXAMPLE, WHEN CHANGING A TIRE. THE WHEEL RESTING ON THE GROUND COULD CAUSE THE VEHICLE TO MOVE. THE TIRE AND WHEEL MUST ALWAYS BE PROPERLY MATCHED. DO NOT MOUNT A 16-INCH TIRE ON A 16.5-INCH WHEEL. FAILURE TO ADHERE TO THESE INSTRUCTIONS COULD RESULT IN AN EXPLOSIVE SEPARATION AND CAUSE SERIOUS BODILY INJURY OR DEATH. IT IS VERY IMPORTANT TO DETERMINE THE SIZE OF EACH COMPONENT BEFORE ANY ASSEMBLY OPERATIONS COMMENCE. DO NOT MOUNT A 16.5-INCH TIRE ON A 16-INCH WHEEL. THE TIRE CAN COME OFF WITHOUT WARNING. AFTERMARKET AEROSOL TIRE SEALANTS ARE EXTREMELY FLAMMABLE. ALWAYS QUESTION CUSTOMER TO MAKE SURE THESE PRODUCTS HAVE NOT BEEN USED. ALWAYS WEAR SAFETY GOGGLES OR A FACE SHIELD WHEN PERFORMING ANY WORK WITH TIRE AND WHEEL ASSEMBLIES. CAUTION: Reduce the air pressure as much as possible by pushing the valve core plunger in prior to removing the valve core. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service Precautions > Technician Safety Information > Page 8171 Wheels: Vehicle Damage Warnings WARNING: USE ONLY WHEELS AND LUG NUTS THAT HAVE BEEN DESIGNED FOR 1997 FORD TRUCKS. AFTERMARKET WHEELS OR LUG NUTS MAY NOT FIT OR FUNCTION PROPERLY AND CO=D HOT YOU OR DAMAGE THE VEHICLE. RETIGHTEN AT 800 KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. CAUTION: Do not clean aluminum wheels with steel wool, abrasive-type cleaners or strong detergents. Use Custom Bright Metal Cleaner 8A-19522-A or equivalent meeting Ford specification ESR-M5B194-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service Precautions > Page 8172 Wheels: Description and Operation WARNING: DO NOT MIX DIFFERENT TYPES OF TIRES ON THE SAME VEHICLE SUCH AS RADIAL, BIAS, OR BIAS-BELTED TIRES EXCEPT IN EMERGENCIES (TEMPORARY SPARE USAGE), BECAUSE VEHICLE HANDLING MAY BE SERIOUSLY AFFECTED AND MAY RESULT IN LOSS OF CONTROL. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures. Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase tire wear. Replacement tires should follow the recommended: - Tresses. - Speed rating. - Load range. - Radial construction type. Use of any other tire size or type may seriously affect: - Ride. - Handling. - Speedometer/odometer calibration. - Vehicle ground clearance. - Tire clearance between the body and chassis. - Wheel bearing life. - Brake cooling. Wheels need to be replaced when: - Bent. - Dented. - Heavily rusted. - Leaking. - They have elongated wheel hub bolt holes. - They have excessive lateral or radial runout. A two-piece lug nut is used, containing the nut and a washer. Wheel and tire assemblies are attached by five noncentering lug nuts. When balancing wheels and tires, use T-type balancing weights. The spare tire is mounted under the frame. The valve stem should he on the top side of the tire to reduce the possibility of accidental valve stem air leakage. To equalize tire wear, the tires should be rotated periodically. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Wheels: Symptom Related Diagnostic Procedures Wheels And Tires Symptom Chart, Part 1 Of 4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8175 Wheels And Tires Symptom Chart, Part 2 Of 4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8176 Wheels And Tires Symptom Chart, Part 3 Of 4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8177 Wheels And Tires Symptom Chart, Part 4 Of 4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8178 Wheels: Component Tests and General Diagnostics Leaks 1. Replace or repair any wheel that leaks air. CAUTION: Do not attempt to repair aluminum wheels that leak air. If repairs are made to the wheel, the structural integrity of the wheel can be lost. Replace any aluminum wheel that leaks air. Runout TEST DESCRIPTION Excessive radial and lateral runout of a wheel and tire assembly can cause roughness, vibration, wheel tramp, tire wear, and steering wheel tremor. Before checking runout and to avoid false readings caused by temporary flat spots in the tires, check runout only after the vehicle has been driven far enough to warm tires. The extent of the runout is measured with Radial Runout Gauge. All measurements are made on the vehicle with the tires inflated to recommended inflation pressures and with the front wheel bearings adjusted to specifications. TIRE RUNOUT Use Radial Runout Gauge to measure (A) radial runout of the tire at the center and outside ribs of the tread face. Mark the high points of radial runout for future reference. Radial runout should not exceed specifications. WHEEL RUNOUT Measure (B) radial and (C) lateral wheel runout at the positions shown. Runout should not exceed specifications. Wheel Centering 0-Ring Seal The front hub and rear axle wheel pilots are fitted with rubber O-rings which help center the wheels. Remove the O-ring and clean the machined groove and clean and lubricate the O-ring if required. Replace the O-ring if damaged. O-rings should be pulled on (not pushed) so that the yellow paint identification stripe is visible after installation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Page 8179 Wheels: Service and Repair REMOVAL 1. Loosen the lug nuts. (1) Remove the center cap. (2) With the weight of the vehicle on the wheels, loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. 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 MA Y RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. (1) Remove the lug nuts. (2) Remove the wheel and tire assembly. INSTALLATION 1. Clean the wheel hub mounting surface. WARNING: WHEN A WHEEL IS INSTALLED, ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL PRESENT ON THE MOUNTING SURFACES OF THE WHEEL OR THE SURFACE OF THE WHEEL HUB, BRAKE DRUM OR BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL TO METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUTS TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. 2. Install the tire and wheel assembly. (1) Inspect the wheel centering O-ring. Replace if damaged. (2) Position the tire and wheel assembly. (3) Install the lug nuts, hand-tight, then lower the vehicle NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Page 8180 3. Tighten the lug nuts in sequence. 4. Install the center cap. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8185 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8186 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8187 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8188 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8189 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8190 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8191 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8192 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8193 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8194 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8195 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8196 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8197 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8198 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8199 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8200 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8201 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8202 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8203 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8204 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8205 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8206 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8207 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8208 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8209 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8210 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8211 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8212 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8213 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8214 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8215 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8216 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8217 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8218 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8219 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8220 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8221 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8222 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8223 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8224 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8225 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8226 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8227 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8228 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8229 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8230 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8231 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8232 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8233 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8234 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8235 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8236 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8237 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8238 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8239 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8240 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8241 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8242 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8243 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8244 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8245 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8246 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8247 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8248 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8249 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8250 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8251 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8252 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8253 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8254 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8255 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8256 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8257 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8258 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8259 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8260 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8261 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8262 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8263 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8264 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8265 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8266 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8267 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8268 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8269 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8270 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8271 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8272 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8273 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8274 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8275 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8276 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8277 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 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. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8278 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 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. 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 the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8279 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 8280 Wheel Bearing: Specifications Rear Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front REMOVAL NOTE: The wheel bearing and hub are replaced as an assembly. 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the wheel and tire assembly. 3. Remove the front disc brake rotor. 4. Remove the front wheel hub nut. (1) Remove the cotter pin. (2) Remove the retainer. (3) Remove the nut. 5. Remove the front disc brake rotor shield. (1) Remove the bolts. (2) Remove the front disc brake rotor shield. 6. Remove the front brake anti-lock sensor. (1) Remove the bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 8283 (2) Remove the front brake anti-lock sensor. 7. Remove the wheel hub. (1) Remove the bolts. (2) Push the CV joint inboard. Remove the wheel hub. CAUTION: Do not over extend CV joint and boots when removing the hub and bearing assembly. NOTE: The CV joint is a slip fit into the wheel hub and bearing. A puller will not normally be required. 8. Remove the seal. INSTALLATION 1. Install the seal. - Use Knuckle Seal Replacer, Threaded Drawbar and Bearing Cup Replacer to install the seal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 8284 2. Install the wheel hub. (1) Position the wheel hub on the front wheel driveshaft and joint and into the front wheel knuckle. (2) Install the bolts. 3. Install the front brake anti-lock sensor. (1) Install the front brake anti-lock sensor into the wheel hub. (2) Install the bolt. 4. Install the front disc brake rotor shield and front axle hub nut. (1) Position the front disc brake rotor shield. (2) Install the bolts. (3) Install the front axle hub nut. (4) Install the retainer. (5) Install cotter pin. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 8285 5. Install the front disc brake rotor. 6. Install the tire and wheel assembly. (1) Position the tire and wheel assembly. (2) Install the lug nuts. (3) Tighten the lug nuts in the sequence indicated. (4) Install the center cap. WARNING: WHEN THE WHEEL IS INSTALLED, ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL THAT MAY BE PRESENT ON THE MOUNTING SURFACES OF THE WHEELS OR THE SURFACES OF THE WHEEL HUB, BRAKE DRUM OR BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUT TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. RETIGHTEN AT 800 KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. 7. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 8286 Wheel Bearing: Service and Repair Rear 8.8 Inch Ring Gear Special Tools Special Tools REMOVAL 1. Remove the axle shaft. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 8287 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with debris. Use Impact Slide Hammer and Axle Wheel Bearing Puller to remove the rear wheel bearing and inner wheel bearing oil seal. INSTALLATION 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2Cl92-A. 2. Use Axle Wheel Bearing Replacer with Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-l-C or equivalent meeting Ford specification ESA-MlC75-B. 4. Use Axle Seal Replacer with Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shafts. 9.75 Inch Ring Gear Models With Rear Disc Brakes Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 8288 Special Tools REMOVAL 1. Remove the axle shaft. 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with debris. Use the Impact Slide Hammer and the Axle Bearing Remover to remove the rear wheel bearing and inner wheel bearing oil seal. INSTALLATION 1. Lubricate the new rear axle bearing. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 8289 - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use the Axle Wheel Bearing Replacer with the Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Use the Axle Seal Replacer with the Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Hub Nut 255-345 Nm (188-254 ft.lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose Technical Service Bulletin # 98S14 Date: 980601 Recall - Wheel Lug Nuts Loose 98S14 SAFETY RECALL All 1997 and Certain 1998 Model Year F-150/250 (under 8,500 lbs.) Series Trucks, all 1997 and Certain 1998 Model Year Expeditions and Certain 1998 Navigator Vehicles - Wheel Attachment ^ Original - June, 1998 ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter ^ Questions and Answer Sheet ^ Supplement # 1 ^ Parts Availability - July, 1998 ^ parts Fax letter - July, 1998 ^ Supplement # 2 ^ Parts Availability - September, 1998 ^ Parts Fax Letter - September, 1998 ^ Supplement # 3 ^ Parts Availability - November, 1998 ^ Important Recall/Service Program Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8302 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8303 Attachment I - Administrative Information OASIS OASIS will not be activated until the second owner mailing begins informing owners of lug nut availability. Vehicle involvement for the interim service action can be determined by using OASIS to confirm the vehicle build date. PLEASE NOTE: Before delivery of a new vehicle to a customer, you are required to perform this tightening procedure to all four wheels. Federal law requires that dealers conduct this tightening procedure prior to delivery to a buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1'100 per vehicle. PROMPTLY CORRECT Affected vehicles which are brought to your dealership. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. WARRANTY AND POLICY MANUAL See Sections 5 and 6 of the ACESII Manual. REFUNDS See ACESII Manual, Section 3. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8304 PARTS REQUIREMENTS Initial supply of revised finish lug nuts (permanent corrective action) is limited. Dealers are requested to tighten current lug nuts per the attached procedure in the interim. Parts will be available in the third (3rd) quarter of 1998. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information TWO-PIECE LUG NUT REPLACEMENT INTERIM SERVICE ACTION - LUG NUTS SERVICE PROCEDURE 1. Remove center cap (hubcap) from each wheel. 2. Tighten each lug nut in sequence shown in figure 1 to verify that the nut is at 100 lb-ft. A torque wrench should be used to ensure proper torque. 3. Tighten each lug nut again in sequence, an additional 1/8 to 1/4 turn. 4. Install center cap (hubcap) on each wheel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8305 TWO-PIECE LUG NUT REPLACEMENT AFFECTED VEHICLES: 1997-1998 EXPEDITION/NAVIGATOR AND F-150/250 SERVICE PROCEDURE The following service procedure must be performed on all four (4) wheels. 1. Remove center caps from wheels. 2. Loosen lug nuts on all four (4) wheels. 3. Raise vehicle on hoist. 4. Remove all lug nuts. 5. Remove tire and wheel assemblies. 6. With wire brush, clean back of wheel (brake rotor/drum mating surface) of any foreign material. 7. Inspect all wheel stud holes for damage (cracked or distorted).If cracked or distorted (if a penny can fit through the stud hole), the wheel must be replaced. 8. Inspect all studs. Replace if damaged. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8306 9. Remove and discard hub 0-ring and any remaining pieces from the front and rear hubs. 10. Install wheel and tire assemblies. NOTE: Do not tighten lug nuts to final torque at this time. 11. Install new lug nuts and tighten enough to securely mate wheel against rotor/drum. 12. Lower vehicle and tighten lug nuts in sequence shown to 136 Nm (100 lb-ft). See Figure 4. 13. Install center caps. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8307 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8308 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8309 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8310 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8311 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8312 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8313 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8314 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > NHTSA98V095000 > May > 98 > Recall 98V095000: Lug Nut Replacement Wheel Fastener: Recalls Recall 98V095000: Lug Nut Replacement Year: 1997, 1998 Make: LINCOLN TRUCK, FORD TRUCK Model: NAVIGATOR, EXPEDITION, F150, F250 Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 1520000 Summary: Vehicle Description: Multi-purpose vehicles and light duty pickup trucks. The lug nuts on these vehicles may not create sufficient clamp load allowing wheel movement in relation to the hub/rotor mounting surface. This can result in the loosening of lug nuts, stud fatigue failure, and the potential for a wheel separation from the vehicle, increasing the risk of a vehicle crash. Dealers will inspect the wheel studs and replace the wheel lug nuts. Owner notification is expected to begin July 20, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > NHTSA98V095000 > May > 98 > Recall 98V095000: Lug Nut Defect Wheel Fastener: Recalls Recall 98V095000: Lug Nut Defect NHTSA CAMPAIGN ID Number: 98V095000 Component: WHEELS: LUGS: NUTS: BOLTS Manufacturer: FORD MOTOR COMPANY Year: 1998 Make: FORD TRUCK Model: EXPEDITION Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 1520000 Summary: Vehicle Description: Multi-purpose vehicles and light duty pickup trucks. The lug nuts on these vehicles may not create sufficient clamp load allowing wheel movement in relation to the hub/rotor mounting surface. This can result in the loosening of lug nuts, stud fatigue failure, and the potential for a wheel separation from the vehicle, increasing the risk of a vehicle crash. Owners of these vehicles will be receiving two notifications. The first notification, which began in May 1998, will provide an interim repair procedure until parts become available. This interim procedure can be completed by owners or their dealers. It specifies that the lug nut torque must be verified to be 100 lbs. Then the lug nuts need to be tightened an additional 1/8 to 1/4 turn more. There will be a second owner notification, which is expected to begin July 20, 1998, under which dealers will inspect the wheel studs and replace the wheel lug nuts. Owners will be receiving two notifications. The first notification, which began in May 1998, will provide an interim repair procedure. There will be a second owner notification, which is expected to begin July 20, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose Technical Service Bulletin # 98S14 Date: 980601 Recall - Wheel Lug Nuts Loose 98S14 SAFETY RECALL All 1997 and Certain 1998 Model Year F-150/250 (under 8,500 lbs.) Series Trucks, all 1997 and Certain 1998 Model Year Expeditions and Certain 1998 Navigator Vehicles - Wheel Attachment ^ Original - June, 1998 ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter ^ Questions and Answer Sheet ^ Supplement # 1 ^ Parts Availability - July, 1998 ^ parts Fax letter - July, 1998 ^ Supplement # 2 ^ Parts Availability - September, 1998 ^ Parts Fax Letter - September, 1998 ^ Supplement # 3 ^ Parts Availability - November, 1998 ^ Important Recall/Service Program Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8328 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8329 Attachment I - Administrative Information OASIS OASIS will not be activated until the second owner mailing begins informing owners of lug nut availability. Vehicle involvement for the interim service action can be determined by using OASIS to confirm the vehicle build date. PLEASE NOTE: Before delivery of a new vehicle to a customer, you are required to perform this tightening procedure to all four wheels. Federal law requires that dealers conduct this tightening procedure prior to delivery to a buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1'100 per vehicle. PROMPTLY CORRECT Affected vehicles which are brought to your dealership. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. WARRANTY AND POLICY MANUAL See Sections 5 and 6 of the ACESII Manual. REFUNDS See ACESII Manual, Section 3. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8330 PARTS REQUIREMENTS Initial supply of revised finish lug nuts (permanent corrective action) is limited. Dealers are requested to tighten current lug nuts per the attached procedure in the interim. Parts will be available in the third (3rd) quarter of 1998. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information TWO-PIECE LUG NUT REPLACEMENT INTERIM SERVICE ACTION - LUG NUTS SERVICE PROCEDURE 1. Remove center cap (hubcap) from each wheel. 2. Tighten each lug nut in sequence shown in figure 1 to verify that the nut is at 100 lb-ft. A torque wrench should be used to ensure proper torque. 3. Tighten each lug nut again in sequence, an additional 1/8 to 1/4 turn. 4. Install center cap (hubcap) on each wheel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8331 TWO-PIECE LUG NUT REPLACEMENT AFFECTED VEHICLES: 1997-1998 EXPEDITION/NAVIGATOR AND F-150/250 SERVICE PROCEDURE The following service procedure must be performed on all four (4) wheels. 1. Remove center caps from wheels. 2. Loosen lug nuts on all four (4) wheels. 3. Raise vehicle on hoist. 4. Remove all lug nuts. 5. Remove tire and wheel assemblies. 6. With wire brush, clean back of wheel (brake rotor/drum mating surface) of any foreign material. 7. Inspect all wheel stud holes for damage (cracked or distorted).If cracked or distorted (if a penny can fit through the stud hole), the wheel must be replaced. 8. Inspect all studs. Replace if damaged. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8332 9. Remove and discard hub 0-ring and any remaining pieces from the front and rear hubs. 10. Install wheel and tire assemblies. NOTE: Do not tighten lug nuts to final torque at this time. 11. Install new lug nuts and tighten enough to securely mate wheel against rotor/drum. 12. Lower vehicle and tighten lug nuts in sequence shown to 136 Nm (100 lb-ft). See Figure 4. 13. Install center caps. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8333 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8334 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8335 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8336 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8337 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8338 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8339 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98S14 > Jun > 98 > Recall - Wheel Lug Nuts Loose > Page 8340 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > NHTSA98V095000 > May > 98 > Recall 98V095000: Lug Nut Replacement Wheel Fastener: All Technical Service Bulletins Recall 98V095000: Lug Nut Replacement Year: 1997, 1998 Make: LINCOLN TRUCK, FORD TRUCK Model: NAVIGATOR, EXPEDITION, F150, F250 Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 1520000 Summary: Vehicle Description: Multi-purpose vehicles and light duty pickup trucks. The lug nuts on these vehicles may not create sufficient clamp load allowing wheel movement in relation to the hub/rotor mounting surface. This can result in the loosening of lug nuts, stud fatigue failure, and the potential for a wheel separation from the vehicle, increasing the risk of a vehicle crash. Dealers will inspect the wheel studs and replace the wheel lug nuts. Owner notification is expected to begin July 20, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > NHTSA98V095000 > May > 98 > Recall 98V095000: Lug Nut Defect Wheel Fastener: All Technical Service Bulletins Recall 98V095000: Lug Nut Defect NHTSA CAMPAIGN ID Number: 98V095000 Component: WHEELS: LUGS: NUTS: BOLTS Manufacturer: FORD MOTOR COMPANY Year: 1998 Make: FORD TRUCK Model: EXPEDITION Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 1520000 Summary: Vehicle Description: Multi-purpose vehicles and light duty pickup trucks. The lug nuts on these vehicles may not create sufficient clamp load allowing wheel movement in relation to the hub/rotor mounting surface. This can result in the loosening of lug nuts, stud fatigue failure, and the potential for a wheel separation from the vehicle, increasing the risk of a vehicle crash. Owners of these vehicles will be receiving two notifications. The first notification, which began in May 1998, will provide an interim repair procedure until parts become available. This interim procedure can be completed by owners or their dealers. It specifies that the lug nut torque must be verified to be 100 lbs. Then the lug nuts need to be tightened an additional 1/8 to 1/4 turn more. There will be a second owner notification, which is expected to begin July 20, 1998, under which dealers will inspect the wheel studs and replace the wheel lug nuts. Owners will be receiving two notifications. The first notification, which began in May 1998, will provide an interim repair procedure. There will be a second owner notification, which is expected to begin July 20, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Fastener Wheel Fastener: Specifications Wheel Fastener TORQUE SPECIFICATIONS Wheel Lug Nuts: 113-153 Nm (83-112 ft. lbs.) GENERAL SPECIFICATIONS Wheel Stud And Lug Nuts (Metric): M12 x 1.75 - 19 mm Hex Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Fastener > Page 8351 Wheel Fastener: Specifications Wheel Stud GENERAL SPECIFICATIONS Wheel Stud And Lug Nuts (Metric) ........................................................................................................................................... M12 x 1.75 - 19 mm Hex Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 8352 Wheel Fastener: Service and Repair REMOVAL 1. Remove the wheel hub. 2. Remove the damaged lug bolts. CAUTION: Do not press on bearing when removing or installing lug bolts. INSTALLATION 1. Install the new lug bolts. CAUTION: Do not press on bearing when removing or installing lug bolts. 2. Install the wheel hub. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications Accumulator HVAC: Specifications Suction Accumulator Clamp Bracket Bolt .................................................................................................................................... 9-11.2 Nm (80-100 Lb-In) Suction Accumulator Fitting ...................................................................................................................................................... 25.5-34.5 Nm (19-25 Lb-Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8357 Accumulator HVAC: Description and Operation NOTE: Replacement of the suction accumulator/drier is necessary any time a major component of the refrigerant system is replaced. Major components include: - A/C condenser core - A/C compressor - A/C evaporator core - a refrigerant hose/line An A/C evaporator core orifice or O-ring seal is not considered a major component but the A/C evaporator core orifice should be replaced whenever the A/C compressor is replaced for lack of performance. In addition to the preceding condition, the suction accumulator/drier should also be replaced if one of the following conditions exist: - The suction accumulator/drier is perforated. - The refrigerant system has been opened to the atmosphere for a period of time longer than required to make a minor repair. - There is evidence of moisture in the system such as internal corrosion of metal refrigerant lines or the refrigerant oil is thick and dark. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8358 The suction accumulator/drier is mounted to the A/C accumulator bracket to the right of the vehicle centerline. The inlet tube of the suction accumulator/drier attaches directly to the A/C evaporator core outlet tube and the outlet tube of the suction accumulator/drier attaches to the A/C manifold and tube. After entering the inlet of the suction accumulator/drier, heavier oil-laden refrigerant contacts an internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the canister. - A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. - As the heavier mixture passes through the small diameter liquid bleed hole, it has a second chance to vaporize and recirculate through the A/C compressor without causing compressor damage due to slugging. - A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out refrigerant system contaminant particles. - A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system. - A fitting located on the top of the suction accumulator/drier is used to attach the A/C cycling switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C cycling switch can be removed without discharging the A/C system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8359 Accumulator HVAC: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Recover the refrigerant. 3. Disconnect the A/C cycling switch electrical connector. 4. Disconnect the manifold and tube fitting. CAUTION: Use a back-up wrench to prevent damage to the tubes. 5. Remove the suction accumulator bracket clamp bolt. 6. Disconnect the suction accumulator/drier spring lock coupling from the A/C evaporator core. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8360 7. Remove the suction accumulator/drier. 8. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION 1. Follow the removal procedure in reverse order. - Service the replacement suction accumulator/drier with the correct amount of Motorcraft YN-12b Refrigerant Oil F2AZ-19577-AB or equivalent meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Specifications > Air Door Actuator Air Door Actuator / Motor: Specifications Air Door Actuator Air Inlet Door Vacuum Motor Screws ................................................................................................................................................. 2-3 Nm (18-27 Lb-In) Panel/Defrost Door Vacuum Motor Screws ......................................................................................................................................... 2-3 Nm (18-27 Lb-In) Panel/Floor Door Vacuum Motor Screws ............................................................................................................................................ 2-3 Nm (18-27 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Specifications > Air Door Actuator > Page 8366 Air Door Actuator / Motor: Specifications Blend Door Motor Electric Blend Door Actuator Screws .................................................................................................................................................. 2-3 Nm (18-27 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Auxiliary Blend Door Actuator Auxiliary Blend Door Actuator Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Auxiliary Blend Door Actuator > Page 8369 Blend Door Actuator Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Auxiliary Blend Door Actuator > Page 8370 Console Blend Door Actuator Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 8371 Air Door Actuator / Motor: Description and Operation The A/C electric blend door actuator is located on the plenum assembly. - Its function is to move the air temperature blend door on command from the control assembly. - The A/C electric blend door actuator contains a reversible electric motor and a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the air temperature blend door. - A 5 volt signal is applied to the ends of the potentiometer. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the Electronic Automatic Temperature Control (EATC) module and is compared to the desired wiper voltage determined by the EATC module. The control module then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the desired wiper voltage. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator Air Door Actuator / Motor: Service and Repair Air Door Actuator Air Inlet Door REMOVAL 1. Remove the plenum chamber. 2. Remove the air inlet door vacuum control motor. 1 Disconnect the vacuum line. 2 Remove the vacuum control motor screws. 3 Remove the air inlet door vacuum control motor. - Rotate vacuum control motor to disconnect the vacuum control motor rod from air inlet door lever. INSTALLATION 1. Follow the removal procedure in reverse order. Defrost/Panel REMOVAL 1. Carefully pry to release the four clips and remove the upper instrument panel steering column cover. NOTE: To allow access to the steering column cover, shift to transmission range 1 and engage the parking brake. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 8374 2. Pull to release the three clips and remove the instrument panel fuse door. 3. Position the hood latch release handle aside. 1 Remove the screws. 2 Position the hood latch release handle aside. 4. Position the parking brake release handle aside. 1 Remove the screws. 2 Position the parking brake release handle aside. 5. If equipped, remove the instrument panel finish panel. - Remove push clips and release the expander clip. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 8375 6. Remove the lower instrument panel steering column cover. 1 Remove the bolts. 2 Remove the upper instrument panel steering column cover. 7. Remove the panel/defrost door vacuum control motor. 1 Disconnect the vacuum line. 2 Remove the pushnut. 3 Remove the vacuum control motor screws. 4 Remove the panel/defrost door vacuum control motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 8376 1. Follow the removal procedure in reverse order. Floor/Panel REMOVAL 1. If equipped, remove the floor duct panel. - Remove the pushpins and release the expander clip. 2. Remove the RH instrument panel brace. 1 Remove the nut. 2 Remove the bolt. 3 Remove the brace. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 8377 3. Remove the LH instrument panel lower nut and position the brace aside. 4. Remove the floor duct. 1 Remove the two screws (one each side). 2 Remove the floor duct. 5. Remove the panel/floor door vacuum control motor. 1 Disconnect the vacuum line connector. 2 Remove the vacuum control motor screws. 3 Slide the rod out of the door and remove the panel/floor door vacuum control motor. NOTE: Rotate the vacuum control motor to disconnect the vacuum control motor rod from the panel/floor door. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 8378 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 8379 Air Door Actuator / Motor: Service and Repair Blend Door Motor Temperature Blend Door Actuator Warning: To avoid accidental deployment and possible injury, the backup power supply must be depleated before repairing or replacing any front or side air bag supplemental restraint (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies ( if equipped ). 1. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with floor console 2. Remove the floor console. All vehicles 3. Remove the floor duct panel. - Remove the pin-type retainers and release the expander clip. 4. Remove the RH instrument panel brake. 1. Remove the nut. 2. Remove the bolt. 3. Remove the brace. 5. Remove the LH instrument panel lower nut and position the brace aside. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 8380 6. Disconnect the restraints control module (RCM) electrical connector. 7. Remove the RCM and bracket assembly. 1. Remove the bracket retaining bolts. 2. Remove the RCM and bracket assembly. Vehicles equipped with rear airflow duct 8. Cut the rear seat airflow duct along both sides. - Fold back carpet. - Cut rear seat airflow duct. 9. Fold the air duct rearwards. All vehicles Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 8381 10. Remove the floor duct. 1. Remove the two screws (one each side). 2. Remove the floor duct. 11. Remove the electronic blend door actuator. 1. Disconnect the connector. 2. Remove the screws. 3. Pull down to release the actuator shaft and remove the electronic blend door actuator. Installation 1. Install the electronic blend door actuator. 1. Connect the actuator shaft. 2. Install the screws. 3. Connect the connector. 2. Install the floor duct. 1. Install the floor duct. 2. Install the two screws (one each side). Vehicles equipped with rear airflow duct Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 8382 3. Zip-tie the rear airflow duct to floor duct. 4. Reposition the carpet. All vehicles 5. Install the RCM and bracket assembly. 6. Connect the restraints control module (RCM) electrical connector. 7. Install the LH instrument panel lower nut. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 8383 8. Install the RH instrument panel brace. - Install the brace. - Install the nut. - Install the bolt. 9. Install the floor duct panel. - Install the pin-type retainers and release the expander clip. Vehicles equipped with floor console 10. Install the floor console. All vehicles 11. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC Air Door Position Sensor / Switch: Diagrams Air Door Position Sensor / Switch, HVAC Front Mode Potentiometer Rear Mode Potentiometer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC > Page 8388 Air Door Position Sensor / Switch: Diagrams Blend Door Position Sensor Front Blend Potentiometer Rear Blend Potentiometer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications Air Duct: Specifications Demister Adapter Screw ...................................................................................................................... ................................................ 2-3 Nm (20-30 Lb-In) Demister Nozzle and Duct Screws ....................................................................................................................................................... 2-3 Nm (18-27 Lb-In) Floor Duct Screw ..................................................................................................... ............................................................................ 2-3 Nm (18-27 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defrost Nozzles and Side Demister Duct Air Duct: Service and Repair Defrost Nozzles and Side Demister Duct REMOVAL 1. Remove the plenum chamber. 2. Remove the A/C plenum demister adapter. 1 Remove the screw. 2 Remove the A/C plenum demister adapter. 3. Remove the demister nozzle and duct. 1 Remove the screws. 2 Remove the demister nozzle and duct. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defrost Nozzles and Side Demister Duct > Page 8394 Air Duct: Service and Repair Floor Duct REMOVAL 1. Remove the floor duct panel. - Remove the two plastic push pins (one each side) and release the expander clip. 2. Remove the RH instrument panel brace. 1 Remove the nut. 2 Remove the bolt. 3 Remove the brace. 3. Remove the LH instrument panel lower nut and position brace aside. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defrost Nozzles and Side Demister Duct > Page 8395 4. Remove the floor duct. 1 Remove the two screws (one each side). 2 Remove the floor duct. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Specifications Air Register: Specifications Center Instrument Panel Register Screws ............................................................................................................................................ 2-3 Nm (18-27 Lb-In) Instrument Panel Finish Panel Screws .................................................................................................................................................. 2-3 Nm (18-27 Lb-In) LH Instrument Panel Brace Nut ........................................................................................................................................................... 6-8 Nm (53-71 Lb-In) RH Instrument Panel Brace Nut ........................................................................................................................................................... 6-8 Nm (53-71 Lb-In) LH Panel Register Screws ................................................................................ .................................................................................... 2-3 Nm (18-27 Lb-In) RH Panel Register Screws ................................................................................................................................................. ................... 2-3 Nm (18-27 Lb-In) RH Instrument Panel Brace Bolt .......................................................................................................................................................... 6-8 Nm (53-71 Lb-In) Instrument Panel Steering Column Cover ............................................................................................................................................ 2-3 Nm (18-27 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Auxiliary Air Register: Service and Repair Auxiliary REMOVAL 1. Fabricate a removal tool from a 1/8 inch diameter rod. 2. Rotate the A/C register with the removal tool to align the retaining ears with the clearance openings and remove the A/C register. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Auxiliary > Page 8401 Air Register: Service and Repair Center REMOVAL 1. Remove the center instrument panel finish panel. 2. If equipped, disconnect the transfer case rotary control switch electrical connector. 3. Remove the center panel register(s). 1 Remove the screws. 2 Pry back the lock tabs. 3 Remove the panel register. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Auxiliary > Page 8402 Air Register: Service and Repair Left REMOVAL 1. Remove the steering column cover panel. 2. Remove the headlamp switch. 3. Remove the LH instrument panel finish panel. 1 Remove the screws. 2 Remove the instrument panel finish panel. 4. Remove the LH panel register. 1 Remove the screws. 2 Pry back the lock tabs. 3 Remove the LH panel register. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Auxiliary > Page 8403 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Auxiliary > Page 8404 Air Register: Service and Repair Right REMOVAL 1. Remove the instrument panel. 2. Remove the RH panel register. 1 Remove the screws. 2 Remove the RH panel register. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation Ambient Temperature Sensor / Switch HVAC: Description and Operation The A/C ambient air temperature sensor and bracket: - is located in front of the A/C condenser core near the center of the vehicle. - contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the electronic automatic temperature control assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Aspirator: > 00-1-8 > Jan > 00 > A/C - Blower Motor Stays on HIGH Aspirator: Customer Interest A/C - Blower Motor Stays on HIGH Article No. 00-1-8 1/10/00 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH SPEED AFTER DESIRED TEMPERATURE HAS BEEN REACHED - EATC EQUIPPED VEHICLES ONLY ^ AIR CONDITIONING - SYSTEM DOES NOT MAINTAIN SET TEMPERATURE - EATC EQUIPPED VEHICLES ONLY FORD: 1997-2000 EXPEDITION LINCOLN: 1998-2000 NAVIGATOR ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), the blower motor may stay on high after desired temperature is reached and/or the system does not maintain set temperature. ACTION Check for proper connection of the in-car temperature aspirator tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Cut a piece of toilet paper or tissue paper about 3.7x3.7 cm (1.5x1.5") (paper towel will not work). 2. Turn the key on and turn fan speed to HIGH. 3. Select PANEL or VENT mode. 4. Place the piece of tissue paper over the aspirator grille opening in the bezel. If aspiration (suction) is present, the tissue paper should stick to the aspirator grille. 5. Turn the fan OFF. The tissue paper should fall off. 6. If the tissue paper falls off the aspirator grille while the fan is on HIGH, check that the aspirator tube is properly connected at the right bottom corner of the front heater. The black connector on the white flexible tube should be snapped over the black tube connected to the heater plenum. Also, check for kinks and cuts in the aspirator tube. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204100, 205000, 208000, 208200, 208300, 208999 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Aspirator: > 00-1-8 > Jan > 00 > A/C - Blower Motor Stays on HIGH Aspirator: All Technical Service Bulletins A/C - Blower Motor Stays on HIGH Article No. 00-1-8 1/10/00 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH SPEED AFTER DESIRED TEMPERATURE HAS BEEN REACHED - EATC EQUIPPED VEHICLES ONLY ^ AIR CONDITIONING - SYSTEM DOES NOT MAINTAIN SET TEMPERATURE - EATC EQUIPPED VEHICLES ONLY FORD: 1997-2000 EXPEDITION LINCOLN: 1998-2000 NAVIGATOR ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), the blower motor may stay on high after desired temperature is reached and/or the system does not maintain set temperature. ACTION Check for proper connection of the in-car temperature aspirator tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Cut a piece of toilet paper or tissue paper about 3.7x3.7 cm (1.5x1.5") (paper towel will not work). 2. Turn the key on and turn fan speed to HIGH. 3. Select PANEL or VENT mode. 4. Place the piece of tissue paper over the aspirator grille opening in the bezel. If aspiration (suction) is present, the tissue paper should stick to the aspirator grille. 5. Turn the fan OFF. The tissue paper should fall off. 6. If the tissue paper falls off the aspirator grille while the fan is on HIGH, check that the aspirator tube is properly connected at the right bottom corner of the front heater. The black connector on the white flexible tube should be snapped over the black tube connected to the heater plenum. Also, check for kinks and cuts in the aspirator tube. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204100, 205000, 208000, 208200, 208300, 208999 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications Blower Motor: Specifications Blower Motor Screws-Plenum .......................................................................................................................................................... 2-3.5 Nm (18-31 Lb-In) Blower Motor Cover Screws-Plenum .................................................................................................................................................... 1-2 Nm (9-17 Lb-In) Blower Motor Nuts Console .......................................................................................................................................................... 2.1-2.9 Nm (19-25 Lb-In) Blower Motor Cover Screws-Console ............................................................................................................................................ 2.1-2.9 Nm (19-25 Lb-In) Blower Motor Duct Screws-Console .............................................................................................................................................. 2.1-2.9 Nm (19-25 Lb-In) Blower Motor Bolts .................................................................................................. ........................................................................... 2-3 Nm (18-26 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Auxiliary A/C Blower Motor Auxiliary A/c Blower Motor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Auxiliary A/C Blower Motor > Page 8426 Blower Motor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Auxiliary A/C Blower Motor > Page 8427 Console Blower Motor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Auxiliary Blower Motor System Blower Motor: Description and Operation Auxiliary Blower Motor System The auxiliary air conditioning system contains a blower motor which is controlled by the heater blower motor switch on the front or rear auxiliary A/C control. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Auxiliary Blower Motor System > Page 8430 Blower Motor: Description and Operation Heating and Defrosting Blower Motor The blower motor pulls air from the air inlet and forces it into the plenum assembly where it is mixed and distributed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor Blower Motor: Service and Repair Blower Motor REMOVAL 1. If equipped, remove the aftermarket air filter. 2. If equipped, remove the mounting bracket for the removed cover. 3. Disconnect the Christmas tree retainer from the motor mounting plate. 4. Disconnect the connector. 5. Remove the blower motor cover. 1 Remove the three screws. 2 Pry to release the three tabs. 3 Remove the cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 8433 6. Remove the blower motor. 1 Remove the three screws. 2 Remove the blower motor. CAUTION: Carefully remove the blower motor so as not to damage the wheel. 7. Remove the wheel from the blower motor. 1 Remove the push clip. 2 Remove the wheel. 8. Remove the gasket. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 8434 Blower Motor: Service and Repair Center Console Blower Motor REMOVAL 1. Remove the floor console. 2. Remove the floor console support braces. 1 Remove the eight screws. 2 Remove the braces. 3. Remove the blower motor duct. 1 Remove the screws. 2 Remove the duct. 4. Remove the blower motor assembly - Remove the three nuts. - Remove the blower motor from bottom of console. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 8435 5. Disconnect the harness connectors. 6. Remove the blower motor resistor. 1 Disconnect the connector. 2 Remove the bolts. 3 Remove the resistor. 7. Remove the blower motor lower duct cover. 1 Remove the five screws. 2 Remove the duct cover. 8. Remove the blower motor upper duct cover. 1 Remove the three bolts. 2 Remove the duct. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 8436 9. Remove the blower motor. 1 Remove the two bolts. 2 Disconnect the connector. 3 Remove the blower motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 8437 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 8438 Blower Motor: Service and Repair Rear REMOVAL 1. Remove the LH quarter trim panel access cover. 2. Remove the blower motor. 1 Disconnect the electrical connector. 2 Remove the three motor cover bolts. 3 Remove the blower motor cover. 4 Remove the blower motor bolts. 5 Remove the blower motor. 3. Remove the wheel from the blower motor. 1 Remove the push clip. 2 Remove the wheel. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 8442 Blower/Flasher Relay Block The Blower Relay is located in the blower/flasher relay block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications Blower Motor Resistor: Specifications Blower Motor Resistor Bolts ................................................................................................................ ............................................... 2-3 Nm (18-26 Lb-In) Blower Motor Resistor Screws ............................................................................................................................................................ 2-3 Nm (18-27 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Auxiliary Blower Resistors Auxiliary A/c Blower Motor Resistor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Auxiliary Blower Resistors > Page 8448 Blower Motor Resistor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Auxiliary Blower Resistors > Page 8449 Console Blower Motor Resistor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 8450 Blower Motor Resistor: Description and Operation The heater blower motor switch resistor has the following features: - The assembly is located on the passenger side of the plenum assembly behind the glove compartment. - Three resistance elements are mounted on the resistor board to provide four A/C blower motor speeds. - Depending on the heater blower motor switch position, series resistance is added or bypassed in the A/C blower motor circuit to decrease or increase A/C blower motor speed. - An overheating protective device (thermal limiter) will open the resistor coil circuit when the temperature reaches 121°C (250°F) interrupting the blower motor operation in all speeds except HI. - The thermal limiter cannot be reset and is not serviceable. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 8451 Blower Motor Resistor: Service and Repair REMOVAL 1. Remove the LH quarter trim panel access cover. 2. Disconnect the electrical connector. 3. Remove the A/C blower motor resistor. 1 Remove the bolts. 2 Remove the A/C blower motor resistor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Blower Switch Blower Motor Switch: Diagrams Blower Switch Front Blower Motor Switch Rear Blower Motor Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 8456 Rear Integrated Control Panel (Rear Blower Switch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 8457 Blower Motor Switch: Diagrams Blower Switch Illumination Front Blower Switch Illumination Rear Blower Switch Illumination Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch Blower Motor Switch: Testing and Inspection Blower Switch Blower Motor Switch - Component Testing Procedure Blower Motor Switch - Terminal Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 8460 Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 8461 Blower Motor Switch: Testing and Inspection Front Blower Switch Front Blower Motor Switch - Component Testing Procedure Front Blower Motor Switch - Terminal Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 8462 Front Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 8463 Blower Motor Switch: Testing and Inspection Rear Auxiliary Rear Blower Motor Switch - Component Testing Procedure Rear Blower Motor Switch - Terminal Locations Rear Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair Note: Not all of these vehicles were equipped with a Cabin Air Filter. Only vehicles with a filter cover in the location shown have a Cabin Air Filter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Specifications Cabin Temperature Sensor / Switch: Specifications In-Car Temperature Sensor Screws ...................................................................................................................................................... 2-3 Nm (18-27 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Specifications > Page 8470 Cabin Temperature Sensor / Switch: Description and Operation The in-car temperature sensor operates in the following manner: - A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. - An automatic temperature control sensor hose and elbow is connected between the plenum assembly and the in-car temperature sensor. - The automatic temperature control sensor hose and elbow uses air from the plenum assembly air stream to create a suction at the in-car temperature sensor. - The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Specifications > Page 8471 Cabin Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the center instrument panel finish panel. 1 Carefully pry to release the four clips. 2. Disconnect the control switch connector. 3. Remove the screws and the accessory outlet trim panel. 4. Remove the screws. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Specifications > Page 8472 5. Disconnect the electrical connector and remove the sensor from the hose. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications A/C Clutch Air Gap ............................................................................................................................................................ 0.35-0.85 mm (0.014-0.033 inch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8477 Compressor Clutch: Description and Operation A/C compressor and Clutch Assembly NOTE: - Internal A/C compressor components are not serviced separately. The FS-10 A/C compressor is serviced only as an assembly. The A/C clutch, A/C clutch pulley, A/C clutch field coil and the shaft seal are serviceable. - Whenever the A/C compressor is replaced, also replace the suction accumulator/drier and the A/C evaporator core orifice. The FS-10 A/C compressor has the following characteristics: - A ten-cylinder swashplate design utilizing the tangential design mount. - Displacement of 154 cc (9.4 cubic inch). - A one-piece lip-type seal (replaceable from the front of the A/C compressor) is used to seal it at the shaft opening in the assembly. - Five double-acting pistons operate within the cylinder assembly. The pistons are actuated by a swashplate that changes the rotating action of the shaft to a reciprocating force. - Reed-type discharge valves are located between the cylinder assembly and the head at each end of the A/C compressor. - The A/C compressor uses Motorcraft YN-12b refrigerant oil F2AZ-19577-AB or equivalent meeting Ford specification WSH-M1C231-B. This oil contains special additives required for the A/C compressor. - The A/C compressor oil from vehicles equipped with an FS-10 A/C compressor may have a dark color while maintaining a normal oil viscosity. This is normal for this A/C compressor because carbon from the piston rings will discolor the oil. Compressor Clutch Components The magnetic A/C clutch has the following characteristics: - It drives the compressor shaft. - When battery positive voltage (B+) is applied to the A/C clutch field coil, the clutch disc and hub assembly is drawn toward the A/C clutch pulley. - The magnetic force locks the clutch disc and hub assembly and the A/C clutch pulley together as one unit, causing the compressor shaft to rotate. - When B+ is removed from the A/C clutch field coil, springs in the clutch disc and hub assembly move the clutch plate away from the A/C clutch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8478 pulley. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8479 Compressor Clutch: Adjustments 1. Check the A/C clutch air gap at three equally spaced places between the clutch hub and the A/C clutch pulley. 2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and the compressor shaft until clearance is within specification. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8480 Compressor Clutch: Service and Repair Jaw Puller Coil Pressing Tool Compressor Clutch Holding Tool Differential Side Bearing Puller Field Coil Replacer Shaft Protector Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8481 SPECIAL TOOL(S) REMOVAL 1. Remove the A/C compressor. 2. Remove the bolt. 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Remove the bolt. 3. Remove the A/C clutch and the A/C clutch hub spacer. 1 Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft. 2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft. 4. Remove the pulley snap ring. 5. Remove the A/C clutch pulley. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8482 6. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Install the Shaft Protector for Coil Removal on the nose opening of the A/C compressor. 3 Install the Differential Side Bearing Puller. 4 Remove the A/C clutch field coil. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. INSTALLATION 1. Clean the A/C clutch field coil and pulley mounting surfaces. 2. Install the A/C clutch field coil. 1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector properly positioned. 2 Place the Field Coil Replacer on the A/C clutch field coil. 3 Place the Coil Pressing Tool on the Field Coil Replacer. 4 Use the 2-Jaw Puller to install the A/C clutch field coil until bottomed completely against the A/C compressor. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. 3. Install the A/C clutch pulley. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be properly aligned during installation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8483 4. Install the pulley snap ring with the bevel side out. 5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. 6. Install the A/C clutch. 7. Install the bolt. 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Tighten the bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8484 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8485 Compressor Clutch: Tools and Equipment Jaw Puller Coil Pressing Tool Compressor Clutch Holding Tool Differential Side Bearing Puller Field Coil Replacer Shaft Protector Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair Compressor Clutch Coil: Service and Repair Jaw Puller Coil Pressing Tool Compressor Clutch Holding Tool Differential Side Bearing Puller Field Coil Replacer Shaft Protector Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 8489 SPECIAL TOOL(S) REMOVAL 1. Remove the A/C compressor. 2. Remove the bolt. 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Remove the bolt. 3. Remove the A/C clutch and the A/C clutch hub spacer. 1 Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft. 2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft. 4. Remove the pulley snap ring. 5. Remove the A/C clutch pulley. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 8490 6. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Install the Shaft Protector for Coil Removal on the nose opening of the A/C compressor. 3 Install the Differential Side Bearing Puller. 4 Remove the A/C clutch field coil. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. INSTALLATION 1. Clean the A/C clutch field coil and pulley mounting surfaces. 2. Install the A/C clutch field coil. 1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector properly positioned. 2 Place the Field Coil Replacer on the A/C clutch field coil. 3 Place the Coil Pressing Tool on the Field Coil Replacer. 4 Use the 2-Jaw Puller to install the A/C clutch field coil until bottomed completely against the A/C compressor. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. 3. Install the A/C clutch pulley. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be properly aligned during installation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 8491 4. Install the pulley snap ring with the bevel side out. 5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. 6. Install the A/C clutch. 7. Install the bolt. 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Tighten the bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 8492 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Specifications Compressor Clutch Hub: Specifications Compressor Clutch Hub Bolt ............................................................................................................................................................. 11-13 Nm (9-10 Lb-Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair Compressor Shaft Seal: Service and Repair Shaft Seal Protector Shaft Seal Remover Shaft Seal Replacer Snap Ring Remover O-Ring Tool SPECIAL TOOL(S) REMOVAL 1. Remove the A/C clutch from the A/C compressor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 8499 2. Remove the shaft seal felt from the nose of the A/C compressor with the O-ring Remover. 3. Clean the compressor nose area. 4. Insert the tip of the Snap Ring Remover into one of the snap ring eyes. 5. Rotate the Snap Ring Remover to position the tool tip and the snap ring eye closest to the A/C compressor shaft. 6. Pull the Snap Ring Remover up quickly while keeping the tool shaft against the side of the nose opening and remove the snap ring. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 8500 7. Engage the Shaft Seal Remover into the inside diameter of the shaft seal. 8. Turn the tool handle clockwise to expand the tool tip inside of the shaft seal. 9. Pull the seal from the A/C compressor. INSTALLATION 1. Clean the A/C compressor nose area. CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials to enter the A/C compressor. 2. Place the shaft seal on the Shaft Seal Protector. Lubricate the shaft seal and the Shaft Seal Protector with Motorcraft YN-12b refrigerant oil F2AZ-19577-AB or equivalent meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 8501 3. Position the shaft seal and the Shaft Seal Protector over the A/C compressor shaft. 4. Push the shaft seal onto the A/C compressor shaft with the Shaft Seal Replacer until seated. 5. Install the shaft seal snap ring. 6. Perform the A/C Compressor- External Leak Test. 7. Install the shaft seal felt. 8. Install the A/C clutch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 8502 Compressor Shaft Seal: Tools and Equipment Shaft Seal Protector Shaft Seal Remover Shaft Seal Replacer Snap Ring Remover O-Ring Tool Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations As shown in the wiring diagrams, these vehicles do not use a compressor cut-off (also called a wide open throttle or WOT) relay. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications Compressor Fitting HVAC: Specifications Manifold Tube Bolt ............................................................................................................................... ........................................... 18-24 Nm (14-18 Lb-Ft) Manifold Tube Fitting ........................................ ....................................................................................................................... 25.5-34.5 Nm (19-25 Lb-Ft) Tube Bracket Nut ...................................................................................................................... ......................................................... 10-14 Nm (8-10 Lb-Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 8509 Compressor Fitting HVAC: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Recover the refrigerant. 3. Remove the manifold and tube assembly. 1 Remove the manifold to compressor bolt. 2 Remove the manifold and tube assembly. 4. Disconnect the A/C pressure cut-off switch electrical connector. 5. Disconnect the manifold and tube fitting at the suction accumulator/drier. 6. Disconnect the A/C condenser core inlet line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 8510 1 Remove the nut. 2 Disconnect the A/C condenser core inlet lines. 7. Remove the A/C pressure cut-off switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 8511 1. Follow the removal procedure in reverse order. - Lubricate the O-ring seals with Motorcraft YN-12b refrigerant oil F2AZ-19577-AB or equivalent meeting Ford specification WSH-M1C231-B. - Apply Pipe Sealant with Teflon(R) D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-A2 and ESR-M18P7-A to the threads of the A/C manifold retaining bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications A/C Condenser Bracket Bolts ...................................................................................................................................................... 7.6-10.4 Nm (66-92 Lb-In) A/C Condenser Line Nuts .............................................................................................................................................................. 6.8-9.2 Nm (61-82 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8515 Condenser HVAC: Description and Operation NOTE: Whenever an A/C condenser core is replaced, it is also necessary to replace the suction accumulator/drier. The A/C condenser core has the following characteristics: - It is an aluminum fin and tube design heat exchanger located in front of the vehicle radiator. - It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and by condensing gas to liquid refrigerant as it is cooled. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8516 Condenser HVAC: Testing and Inspection ON-VEHICLE LEAK TEST 1. Discharge and recover the refrigerant. 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the A/C test fitting set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the manifold gauge set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8517 Condenser HVAC: Service and Repair REMOVAL CAUTION: To prevent refrigeration system contamination, whenever the A/C condenser core is replaced, also replace the suction accumulator/drier. NOTE: If an A/C condenser core leak is suspected, the A/C condenser core must be leak-tested before it is removed from the vehicle. 1. Disconnect the battery ground cable. 2. Recover the refrigerant. 3. Remove the radiator. 4. Disconnect the A/C condenser core inlet and outlet lines. 1 Remove the nuts. 2 Disconnect the A/C condenser core inlet and outlet hoses. 5. Remove the A/C condenser core. 1 Remove the bolts. 2 Remove the brackets. 3 Remove the A/C condenser core. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8518 1. Follow the removal procedure in reverse order. - Service the replacement A/C condenser core with the correct amount of Motorcraft YN-12b refrigerant oil F2AZ-19577-AB or equivalent meeting Ford specification WSH-M1C231-B. - Lubricate the O-ring seals with Motorcraft YN-12b refrigerant oil F2AZ-19577-AB or equivalent meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Specifications Control Assembly: Specifications Climate Control Assembly Screws ....................................................................................................................................................... 2-3 Nm (18-27 Lb-In) Auxiliary Air Conditioning and Heater Assembly Bolts ................................................................................................................ 5.2-7.2 Nm (46-64 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Blend Door Potentiometer Function Selector Switch (Blend Door Potentiometer) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Blend Door Potentiometer > Page 8524 Function Selector Switch (Blower Motor Switch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Blend Door Potentiometer > Page 8525 Function selector switch (Illumination) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Blend Door Potentiometer > Page 8526 Function selector switch (Mode Selector Switch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Auxiliary Air Conditioning and Heating System Control Assembly: Description and Operation Auxiliary Air Conditioning and Heating System The auxiliary A/C system has dual controls for the driver and rear passengers consisting of temperature, blower speed, and mode. The front auxiliary A/C control is mounted in the overhead console. The rear auxiliary A/C control is mounted in a separate console positioned on the roof trim panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Auxiliary Air Conditioning and Heating System > Page 8529 Control Assembly: Description and Operation With Air Conditioning The climate control assembly has three system controls: - The A/C heater function selector switch combines a vacuum selector valve with two electrical switches to supply battery positive voltage (B+) to the A/C clutch circuit and the blower motor control circuit. - The temperature selection is accomplished with a potentiometer connected to the electric blend door actuator that controls positioning of the temperature blend door. Movement of the control knob from COOL (Blue) to WARM (Red) causes a corresponding movement on the air temperature control door and determines the temperature that the system will maintain. - The blower motor switch controls blower motor speed by adding or by passing resistors in the heater blower motor switch resistor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Conditioning and Heater Assembly Control Assembly: Service and Repair Air Conditioning and Heater Assembly REMOVAL 1. Discharge and recover the refrigerant. 2. Drain the engine cooling system. 3. Remove the LH quarter trim panel. 4. Disconnect the electrical connectors. 5. Disconnect the heater core hose couplings. 6. Remove the evaporator case drain hose. 7. Disconnect the A/C evaporator lines from the A/C evaporator expansion valve. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Conditioning and Heater Assembly > Page 8532 8. Remove the A/C outlet duct. 1 Remove the pushpin. 2 Remove the A/C outlet duct. 9. Remove the auxiliary air conditioning and heater assembly. 1 Remove the three bolts. 2 Remove the auxiliary air conditioning and heater assembly. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Conditioning and Heater Assembly > Page 8533 Control Assembly: Service and Repair Climate Control Switches REMOVAL 1. Remove the control assembly. 2. Remove the function selector. 1 Depress the snap tabs. 2 Remove the function selector. NOTE: The knob will drop off as the function selector is removed. 3. Remove the temperature blend control switch. 1 Remove the screw. 2 Rotate and pull the temperature blend control. NOTE: The knob will drop off as the temperature blend control switch is removed. 4. Remove the blower motor switch. 1 Depress the snap tabs. 2 Remove the blower motor switch. NOTE: The knob will drop off as the blower motor switch is removed. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Conditioning and Heater Assembly > Page 8534 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Conditioning and Heater Assembly > Page 8535 Control Assembly: Service and Repair Front Control Assembly REMOVAL 1. Remove the overhead console. 1 Remove the screw. 2 Carefully release the three clips and slide the overhead console forward. 3 Disconnect the electrical connectors. 2. Remove the auxiliary climate control assembly from the bezel. 1 Disconnect the electrical connectors. 2 Remove the screws. 3 Remove the climate control assembly. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Conditioning and Heater Assembly > Page 8536 Control Assembly: Service and Repair Rear Control Assembly REMOVAL 1. Remove the auxiliary climate control assembly. 1 Slide the assembly forward and downward. 2 Disconnect the electrical connectors. 2. Remove the auxiliary climate control assembly from the bezel. 1 Disconnect the electrical connectors. 2 Remove the screws. 3 Remove the climate control assembly. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Conditioning and Heater Assembly > Page 8537 Control Assembly: Service and Repair With Manual A/C REMOVAL 1. Disconnect the battery ground cable. 2. Remove the center instrument panel finish panel. - Carefully pry to release the four clips. 3. Disconnect the control switch connector. 4. Remove the climate control head. 1 Remove the screws. 2 Pull out the climate control head. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Conditioning and Heater Assembly > Page 8538 5. Disconnect the climate control head. 1 Disconnect the electrical connectors. 2 Disconnect the vacuum line connector. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control Control Module HVAC: Description and Operation Blower Motor Speed Control The A/C blower motor speed control is a Pulse Width Modulated (PWM) type which provides variable blower speed control of the blower motor. The A/C blower motor speed control is controlled by switching the control signal voltage of 5 volts OFF and ON 2,000 times per second. By varying the ratio of time on (+5 volts) to time off (0 volts), the EATC module tells the A/C blower motor speed control how fast the blower motor should run. The A/C blower motor speed control has the following features: - Controls the speed of the blower motor by switching the motor OFF and ON 40,000 times per second by varying the ratio of time ON (+14 volts) to time OFF (0 volts). - Has circuitry to protect the blower motor from burning out in the event of a locked rotor condition. - Can compensate for changes in battery positive voltage (B+) which prevents the blower speed from slowing down when the engine is idling and will provide up to a maximum of 30 amperes for blower motor operation with battery voltages between 10 and 16 volts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control > Page 8543 Control Module HVAC: Description and Operation Electronic Climate Control Module The Electronic Automatic Temperature Control (EATC) module, located in the instrument panel, has the following features: - 11 push buttons - a blower speed override thumbwheel for manual input - a vacuum fluorescent display for displaying set temperature, ambient temperature, function and Diagnostic Trouble Codes (DTCs) - an On-Board Diagnostic (OBD) feature to supply the technician with Diagnostic Trouble Codes (DTCs). These DTCs direct the technician to the inoperative component. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control Control Module HVAC: Service and Repair Blower Motor Speed Control REMOVAL 1. Disengage the stops and lower the glove compartment door. 2. Disengage the blower motor speed control mounting bracket from the instrument panel. 3. Disconnect the connectors. 4. Disengage the retaining tabs and remove the blower motor speed control from the mounting bracket. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 8546 Control Module HVAC: Service and Repair Electronic Climate Control Module REMOVAL 1. Disconnect the battery ground cable. 2. Remove the center instrument panel finish panel. - Carefully pry to release the four clips. 3. Disconnect the control switch connector. 4. Remove the screws from the electronic automatic temperature control module. 5. Remove the electronic automatic temperature control module. 1 Disconnect the electrical connectors. 2 Remove the nuts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 8547 3 Disconnect the vacuum harness connector and remove the EATC module. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 8548 Control Module HVAC: Service and Repair Illumination Bulbs REMOVAL 1. Remove the control assembly. 2. Unsnap the bezel and pivot it open. - To replace the general illumination bulbs, unscrew the lamp holders and remove the bulb. - To replace the HI/LO bulb, cut the wires close to the bulb base, splice the wires to the new bulb and wrap the splice with electrical tape. NOTE: Place the module upside-down on a non-marring surface. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Specifications Coupler HVAC: Specifications Peanut Fittings ..................................................................................................................................... ........................................... 6.8-9.2 Nm (61-82 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Specifications > Page 8552 Coupler HVAC: Description and Operation Spring Lock Coupling The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a circular cage. - When the coupling is connected together, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting. - The garter spring and cage then prevent the flared end of the female fitting from pulling out of the cage. - Three O-ring seals are used to seal between the two halves of the A/C condenser core couplings, all other couplings have two O-ring seals. - These O-ring seals are green in color and are made of special material. - Use only the green O-ring seals listed in the Ford Master Parts Catalog for the spring lock coupling. - A plastic indicator ring is used on the spring lock couplings of the A/C evaporator core to indicate, during vehicle assembly, that the coupling is connected. Once the coupling is connected, the indicator ring is no longer necessary but will remain captive by the coupling near the cage opening. - The indicator ring may also be used during service operations to indicate connection of the coupling. - An A/C tube lock coupling clip may be used to secure the coupling but is not required. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting Coupler HVAC: Service and Repair Peanut Fitting DISCONNECT 1. Remove the nut from the peanut fitting. CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting. 2. Pull the peanut fitting apart. 3. Remove the O-ring seal with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seal. They can cause axial scratches across the O-ring groove resulting in refrigerant leaks. CONNECT 1. Clean all dirt or foreign material from the fittings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 8555 2. Install the O-ring seal. 1 Lubricate the O-ring seal with Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B. CAUTION: Use only new green O-rings. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. 3. Lubricate the inside of the fittings with Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B. 4. Assemble the male and female fittings together. NOTE: When properly assembled the male and female fittings should be flush. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 8556 Coupler HVAC: Service and Repair Spring Lock Coupling Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling SPECIAL TOOL(S) DISCONNECT 1. Remove the A/C tube lock coupling clip. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 8557 2. Fit the spring lock coupling disconnect tool to the spring lock coupling. 3. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling spring. 4. Pull the spring lock coupling fittings apart. 5. Remove the O-ring seals with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring grooves resulting in refrigerant leaks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 8558 6. Remove the A/C tube lock coupling spring with a small hooked wire. CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring; this can cause axial scratches across the O-ring grooves resulting in refrigerant leaks. CLEANING 1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod. 2. Cut an abrasive pad from maroon colored 3M Scotch Brite(R) with the dimensions corresponding to the coupling size. Coupling Size Pad Size 3/8 inch 25 X 50 mm (1 X 2 inch) 1/2 inch 25 X 50 mm (1 X 2 inch) 5/8 inch 25 X 76 mm (1 X 3 inch) 3/4 inch 25 X 102 mm (1 X 4 inch) 3. Assemble the pad to the tool. 4. Coat the abrasive pad with Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B. 5. Roll the pad on the tool and install it in a variable speed motor drill. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 8559 6. Polish for 1 minute at moderate speed (less than 1500 rpm) or until the surface is clean and free of scratches or debris. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. 7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves and scratches are still present, replace the component. 9. Clean the O-ring grooves with a 300 mm (12 inch) length of natural fiber string. 1 Loop the string around the grooves and pull the string back and forth. 10. Remove any debris from the grooves with a lint-free cloth. CONNECT 1. Install the A/C tube lock coupling spring. 2. Lubricate the inside of the coupling with Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 8560 3. Install the O-ring seals. 1 Lubricate the O-ring seals with Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B. CAUTION: Use only new green O-rings. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. 4. Connect the spring lock coupling fittings with a twisting motion until the A/C tube lock coupling spring snaps over the flared end of the female fitting. 5. Install the A/C tube lock coupling clip. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications Evaporator Core: Specifications A/C Evaporator to Expansion Valve Lines ..................................................................................................... 12.7-17.3 Nm (10-12 Lb-Ft) (113-154 Lb-In) Evaporator/Heater Core Access Cover Bolts ....................................................................................................................................... 2-3 Nm (18-26 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Auxiliary Evaporator Core: Description and Operation Auxiliary The auxiliary A/C system uses a rear A/C evaporator core which operates in the same manner as the front A/C evaporator core. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Auxiliary > Page 8566 Evaporator Core: Description and Operation Front A/C Evaporator Core NOTE: Whenever an A/C evaporator core is replaced, also replace the suction accumulator/drier. The A/C evaporator core is the plate/fin type with a unique refrigerant flow path. - A mixture of refrigerant and oil enters the bottom of the A/C evaporator core through the A/C evaporator core inlet tube and is routed so it flows through the partitioned first three plate/fin sections. - The next four plate/fin sections are partitioned to force the refrigerant to flow toward the other end of the A/C evaporator core. - Refrigerant then continues over to the remaining five plate/fin sections and then moves out of the A/C evaporator core through the A/C evaporator core outlet tube. - This S-pass flow pattern accelerates the flow of refrigerant and oil through the A/C evaporator core. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 8567 Evaporator Core: Testing and Inspection ON-VEHICLE LEAK TEST 1. Discharge and recover the refrigerant. 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the A/C test fitting set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the manifold gauge set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core: Service and Repair Front REMOVAL CAUTION: To prevent refrigerant system contamination, if you are replacing the A/C evaporator core you must also replace the suction accumulator/drier. NOTE: If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak tested before it is removed from the vehicle. 1. Recover the refrigerant. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 2. Drain the radiator. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 3. Remove the instrument panel. Refer to: "Body and Frame : Interior Trim : Dash Board : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 4. Disconnect the heater water hoses at the heater core. 5. Disconnect the refrigerant line spring lock couplings from the A/C evaporator core. 6. Remove the RH A/C plenum demister adapter. 1 Remove the screw. 2 Remove the RH A/C plenum demister adapter. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front > Page 8570 7. Remove the heater core outlet bracket. 1 Remove the screws. 2 Remove the bracket. 8. Remove the plenum assembly top. 1 Remove the 14 screws. 2 Remove the plenum assembly top. 9. Remove the A/C evaporator core from the plenum assembly. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front > Page 8571 1. Follow the removal procedure in reverse order. - Service the replacement A/C evaporator core with the correct amount of Motorcraft YN-12b refrigerant oil meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front > Page 8572 Evaporator Core: Service and Repair Auxiliary Evaporator Core (Auxiliary) Removal and Installation 1. Remove the air conditioning and heater assembly. See: Heater Core Case/Service and Repair 2. Remove the auxiliary A/C evaporator lines. 3. Remove the evaporator/heater core access cover. 1.Remove the ten bolts. 2.Remove the evaporator/heater core access cover. 4. Remove the A/C evaporator core (19860). 5. To install reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front > Page 8573 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations Expansion Block/Orifice Tube: Locations The A/C evaporator core orifice is located in the A/C evaporator core inlet tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 8577 Expansion Block/Orifice Tube: Description and Operation A/C Evaporator Core Orifice NOTE: The A/C evaporator core orifice should be replaced whenever an A/C compressor is replaced. The A/C evaporator core orifice has the following characteristics: - is located in the A/C evaporator core inlet tube. - has filter screens located on the inlet and outlet ends of the tube body. - The inlet filter screen acts as a strainer for the liquid refrigerant flowing through the A/C evaporator core orifice. - O-rings on the A/C evaporator core orifice prevent the high-pressure liquid refrigerant from by-passing the A/C evaporator core orifice. - Adjustment or service cannot be made to the A/C evaporator core orifice assembly. It must be replaced as a unit. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 8578 Expansion Block/Orifice Tube: Service and Repair Broken Orifice Tube Extractor Fixed Orifice Tube SPECIAL TOOL(S) REMOVAL 1. Remove the condenser to evaporator tube. - For a fixed orifice tube, perform Steps 2 and 3. - For a broken orifice tube, perform Steps 4 and 5. 2. Engage the Fixed Orifice Tube Remover/Replacer to the A/C evaporator core orifice. 3. Hold the tool T-handle stationary and rotate the tool body to remove the A/C evaporator core orifice. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 8579 4. To remove a broken A/C evaporator core orifice; screw the end of the Broken Orifice Tube Extractor into the broken A/C evaporator core orifice. 5. Hold the tool T-handle stationary and rotate the tool body to remove the broken A/C evaporator core orifice. INSTALLATION 1. Lubricate and install the O-ring seals on the A/C evaporator core orifice. 1 Use Motorcraft YN-12b refrigerant oil F2AZ-19577-AB or equivalent meeting Ford specification WSH-M1C231-B. 2. Place the A/C evaporator core orifice into the Fixed Orifice Tube Remover/Replacer. 3. Insert the A/C evaporator core orifice into the condenser to evaporator tube until seated. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 8580 4. Remove the Fixed Orifice Tube Remover/Replacer. 5. Install the condenser to evaporator tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 8581 Expansion Block/Orifice Tube: Tools and Equipment Broken Orifice Tube Extractor Fixed Orifice Tube Remover/Replacer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications Expansion Valve: Specifications A/C Evaporator to Expansion Valve Lines ..................................................................................................... 12.7-17.3 Nm (10-12 Lb-Ft) (113-154 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications > Page 8585 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications > Page 8586 Expansion Valve: Description and Operation An A/C evaporator expansion valve automatically regulates the flow of refrigerant into the auxiliary A/C evaporator core. It is also the dividing point in the system between low- and high-pressure sides. The temperature sensing bulb, measures the temperature of the refrigerant in the suction line and transmits it to the A/C evaporator expansion valve. This temperature variation regulates the refrigerant flow to the auxiliary A/C evaporator core. - When the bulb senses a high temperature, the A/C evaporator expansion valve opens and floods refrigerant through the auxiliary A/C evaporator core. - When the bulb senses a low temperature, the A/C evaporator expansion valve starts closing to shut off the refrigerant to the auxiliary A/C evaporator core. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications > Page 8587 Expansion Valve: Service and Repair REMOVAL 1. Discharge and recover the refrigerant. 2. Remove the quarter trim panel access cover. 3. Disconnect the A/C evaporator core from the A/C evaporator expansion valve. 4. Disconnect the A/C lines from the A/C evaporator expansion valve. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 (V8-281 4.6L SOHC (1998)) 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 8596 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 (V8-281 4.6L SOHC (1998)) 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 8597 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 97-19-11 > Sep > 97 > Heater Core - On Car Pressure Test For Warranty Claim Heater Core: All Technical Service Bulletins Heater Core - On Car Pressure Test For Warranty Claim Article No. 97-19-11 09/15/97 COOLING SYSTEM - "ON-VEHICLE" HEATER CORE PRESSURE TEST REQUIRED FOR WARRANTY CLAIM FORD: 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1993-98 ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: An "On-Vehicle" heater core pressure test is required before replacing any heater core within the warranty period. ACTION: Perform the "On-Vehicle" heater core pressure test by referring to the following heater core leak test procedure. HEATER CORE LEAK TEST PROCEDURE Use the heater core pressure test to determine if the heater core is leaking. Symptoms associated with a leaking heater core include: ^ Engine coolant leaking into the passenger compartment ^ Engine coolant blown onto the windshield during defrost operation ^ Engine coolant odor inside the passenger compartment 1. Partially drain cooling system. 2. Disconnect both heater core hoses. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 97-19-11 > Sep > 97 > Heater Core - On Car Pressure Test For Warranty Claim > Page 8602 3. Attach two (2) pieces of heater hose to the heater core inlet and outlet tubes and clamp (Figure 1). 4. Install Plug (part of 014-R1072) into one (1) heater hose and clamp (Figure 1). 5. Fill heater core and hoses with water. 6. Install Adapter (part of 0144-R1072) into other heater hose and clamp (Figure 1). 7. Attach Radiator/Heater Core Pressure Tester (014-R1072) to Adapter (part of 014-R1072) (Figure 1). 8. Close the bleed valve and the tester and pump air into the heater core until 241 kPa (35 psi) is reached on the tester gauge. 9. Observe the gauge after 3 minutes. The pressure should not drop. If the pressure does drop, there is a leak. Check the hose connections and retest if you find a leak. 10. Replace heater core if pressure drops and hose connections do not leak. 11. Do not replace heater core if pressure does not drop. Pressure test engine cooling system for leaks elsewhere. 12. Reconnect heater core and refill cooling system after all necessary repairs. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208999, 290000, 402000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 (V8-281 4.6L SOHC (1998)) 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 8608 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 (V8-281 4.6L SOHC (1998)) 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 8609 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8610 Heater Core: Specifications Heater Core Bracket Screws .......................................................................................................................................................... 1.5-2.5 Nm (13-22 Lb-In) Heater Core Outlet Bracket Screws ................................................................................................................................................ 1.5-2.5 Nm (13-22 Lb-In) Evaporator/Heater Core Access Cover Bolts ....................................................................................................................................... 2-3 Nm (18-26 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Auxiliary Heater Core: Description and Operation Auxiliary The auxiliary A/C system uses a rear heater core which operates in the same manner as the front heater core. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Auxiliary > Page 8613 Heater Core: Description and Operation Front 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 8614 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require replacement. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. Perform a system inspection by checking the heater system thoroughly. 2. Check the integrity of the heater water hose clamps. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Heater Core-Plugged WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the proper level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot: the heater core may have an air pocket - the heater core may be plugged, or - the thermostat is not working properly. Heater Core-Pressure Test Use the radiator/heater core pressure tester to perform the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the radiator/heater core pressure tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and perform the bench test. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 8615 Heater Core-Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, replace the heater core. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core Heater Core: Service and Repair Back Flushing-Heater Core 1. Once pressure is released, remove the pressure relief cap. WARNING: NEVER REMOVE THE PRESSURE RELIEF CAP WHILE THE ENGINE IS OPERATING OR WHEN THE COOLING SYSTEM IS HOT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE OR PERSONAL INJURY. TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE DEGAS BOTTLE WHEN REMOVING THE PRESSURE RELIEF CAP, WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE PRESSURE RELIEF CAP AND TURN IT SLOWLY. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN RELEASED, (STILL WITH A CLOTH) TURN AND REMOVE THE PRESSURE RELIEF CAP. 2. Partially drain the cooling system. 3. Use cooling system Flush-All, Flush Kit Hardware Package and Drain Kit to backflush the hater core. Use Ford Premium Cooling System Flush F1AZ-19A503-A meeting Ford specification ESR-M14P7A. 4. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 8618 Heater Core: Service and Repair Removal and Installation Front REMOVAL 1. Disconnect the battery ground cable. 2. Drain the radiator. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 3. Remove the instrument panel. Refer to: "Body and Frame : Interior Trim : Dash Board : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 4. Compress the holding tabs and disconnect the heater water hoses at the heater core. 5. Remove the A/C plenum demister adapter. 1 Remove the screw. 2 Remove the A/C plenum demister adapter. 6. Disconnect the vacuum line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 8619 7. Remove the heater core bracket. 1 Remove the two screws. 2 Remove the bracket. 8. Remove the plenum chamber top. 1 Remove the 13 screws. 2 Remove the plenum chamber top. 9. Remove the blend door assembly from the case. 10. Remove the heater core. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 8620 1. Follow the removal procedure in reverse order. Auxiliary REMOVAL 1. Remove the air conditioning and heater assembly. Refer to: "Heater Core Case : Service and Repair" See: Heater Core Case/Service and Repair 2. Remove the evaporator/heater core access cover. 1 Remove the ten bolts. 2 Remove the evaporator/heater core access cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 8621 3. Remove the heater core. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Page 8622 Special Tools Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Specifications Heater Core Case: Specifications A/C Plenum Demister Adapter Screw .................................................................................................................................................. 2-3 Nm (18-27 Lb-In) Plenum Assembly Nuts (Passenger Side) ............................................................................................................................................. 4-6 Nm (36-53 Lb-In) Plenum Assembly Nuts (Engine Side) ................................................................................................................................................. 4-6 Nm (36-53 Lb-In) Plenum Assembly Top Screws ....................................................................................................................................................... 1.5-2.5 Nm (13-22 Lb-In) Plenum Top Screws .................................................................................... .................................................................................... 1.5-2.5 Nm (13-22 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Specifications > Page 8626 Heater Core Case: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Recover the refrigerant. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 3. Drain the radiator. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 4. Remove the instrument panel. Refer to: "Body and Frame : Interior Trim : Dash Board : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 5. Disconnect the heater water hoses at the heater core. 6. Disconnect the refrigerant line spring lock couplings from the A/C evaporator cores. 7. Remove the plenum chamber nuts (engine side). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Specifications > Page 8627 8. Disconnect the A/C vacuum hose from the A/C vacuum check valve. 9. Remove the plenum chamber nuts (interior). 10. Remove the plenum chamber. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Specifications > Page 8628 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8637 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8638 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8644 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8645 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 8646 Heater Hose: Specifications Hose Clamp ......................................................................................................................................... ........................................... 1.6-2.2 Nm (17-22 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line Heater Hose: Service and Repair Front Auxiliary Heater Outlet and Inlet Line REMOVAL NOTE: The front auxiliary heater outlet line is shown; the front auxiliary heater inlet line is similar. 1. Drain the cooling system. 2. Turn the air suspension switch off, if equipped. 3. Raise and support the vehicle. 4. Remove the RH front fender splash shield. 1 Remove the bolts. 2 Remove the pushpins. 3 Remove the front fender splash shield. 5. Remove the four line brackets. 1 Remove the nuts. 2 Remove the bracket by inserting a screwdriver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 6. Disconnect the heater outlet line from the outlet hose coupling. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8649 7. Disconnect the front auxiliary heater outlet line from the rear auxiliary heater outlet line. 1 Remove the nut. 2 Disconnect the line. 8. Cut the heater outlet line in the locations shown. 9. Remove and discard the cut sections. INSTALLATION 1. Install the heater outlet line. - Install the end with the blue tape over the frame. 2. Install the heater outlet line. - Install the end with the red tape over the frame. - Install the end with the yellow tape between the frame and the body vertical flange. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8650 3. Connect the two heater water outlet lines. 1 Connect the fitting. 2 Loosely install the nut. 4. Install the heater water outlet line. - Install the line through the wheel opening. 5. Connect the two heater water outlet lines. 1 Connect the fitting. 2 Loosely install the nut. 6. Tighten the two peanut fittings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8651 7. Install the line brackets. 1 Position the bracket. 2 Install the nut. - Snap the line into the bracket. CAUTION: Verify that clearance exists between the frame and the lines to prevent component damage. NOTE: The bracket must be positioned equally between the white location marks on the line. 8. Connect the heater water outlet line to the engine heater outlet hose coupling. 9. Install the bolts, the pushpins and the front fender splash shield. 10. Lower the vehicle. 11. Turn on the air suspension switch, if equipped. 12. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8652 Heater Hose: Service and Repair Heater Hose Couplings Heater Hose Disconnect Tool SPECIAL TOOL(S) DISCONNECT 1. Depressurize the engine cooling system. WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. Push the Heater Hose Disconnect Tool over the coupling retainer windows to compress the retainer locking tabs. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Tool must be perpendicular to and on the highest point of the coupling. 4. Pull the heater water hose away from the heater core tube. NOTE: A slight twisting motion while pulling on the heater waster hose may be necessary to assist in the removal. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8653 7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer. CONNECT 1. Clean the tubes and lubricate with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESR-M99B112-A. 2. Install a new coupling retainer, spacer, and lubricated O-rings into the quick disconnect coupling housing. 3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the coupling is fully engaged by lightly pulling on the heater water hose. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8654 Heater Hose: Service and Repair Rear Auxiliary Heater Inlet Line REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater inlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8655 9. Remove the four line brackets. 1 Remove the nuts. 2 Remove the bracket by inserting a screwdriver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 10. Cut the line in the positions shown. 11. Remove and discard the cut sections. INSTALLATION 1. Install the heater inlet line. - Install the end with the green tape over the axle between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8656 2. Connect the heater inlet line to the front auxiliary line. 1 Connect the inlet line. 2 Loosely install the nut. 3. Install the heater inlet line. - Install the end with the blue tape between the frame crossmember and the floor pan. 4. Connect the two heater inlet lines. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater inlet line. - Install the end with the red tape between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8657 6. Connect the two heater inlet lines. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater inlet line. - Install the end with the green tape through the floor opening. 8. Connect the two heater inlet lines. 1 Connect the fittings. 2 Loosely install the nut. 9. Tighten the four peanut fittings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8658 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. - Snap the line into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the line. 11. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8659 15. Connect the heater inlet hose coupling. 16. Install the quarter trim access panel. 17. Install the spare tire. 18. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8660 Heater Hose: Service and Repair Rear Auxiliary Heater Outlet Line REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater outlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8661 9. Remove the four line brackets. 1 Remove the nuts. 2 Remove the bracket by inserting a screwdriver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 10. Cut the line in the positions shown. 11. Remove and discard the cut sections. INSTALLATION 1. Install the heater outlet line. - Install the end with the blue tape over the axle between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8662 2. Connect the heater outlet line to the front auxiliary line. 1 Connect the fittings. 2 Loosely install the nut. 3. Install the heater outlet line. - Install the end with the red tape between the frame and the crossmember. 4. Connect the two heater outlet lines. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater outlet line. - Install the end with blue tape between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8663 6. Connect the heater outlet line to the heater outlet line. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater outlet line. - Install the end with the hose through the floor opening. 8. Tighten the four peanut fittings. 9. Install the line brackets. 1 Position the bracket. 2 Install the nut. - Snap the line into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8664 10. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 11. Lower the vehicle. 12. Turn on the air suspension switch, if equipped. 13. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 14. Connect the heater outlet hose coupling. 15. Install the quarter trim access panel. 16. Install the spare tire. 17. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8665 Heater Hose: Service and Repair Removal and Installation REMOVAL 1. Drain the radiator. 2. Disconnect the heater outlet hose at the engine. 3. Disconnect the heater inlet hose at the engine. 1 Loosen the hose clamp. 2 Disconnect the heater inlet hose. 4. Compress the holding tabs and disconnect the heater water hoses at the heater core. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8666 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Page 8667 Heater Hose Disconnect Tool Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Mechanical Specifications High Pressure Safety Valve HVAC: Mechanical Specifications A/C Compressor Pressure Relief Valve Opens at ..................................................................................................................................... 3103 kPa (450 psi) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Mechanical Specifications > Page 8672 High Pressure Safety Valve HVAC: Pressure, Vacuum and Temperature Specifications A/C Compressor Pressure Relief Valve Opens at ..................................................................................................................................... 3103 kPa (450 psi) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > A/C High Pressure Safety Valve High Pressure Safety Valve HVAC: Description and Operation A/C High Pressure Safety Valve An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube to: - relieve unusually high refrigerant system discharge pressure buildups, (3103 kPa and above). - prevent damage to the A/C compressor and other system components. - avoid total refrigerant loss by closing after the excessive pressure has been relieved. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > A/C High Pressure Safety Valve > Page 8675 High Pressure Safety Valve HVAC: Description and Operation Compressor Relief Valve An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube to: - relieve unusually high refrigerant system discharge pressure buildups, (3103 kPa and above). - prevent damage to the A/C compressor and other system components. - avoid total refrigerant loss by closing after the excessive pressure has been relieved. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications A/C Evaporator to Expansion Valve Lines ..................................................................................................... 12.7-17.3 Nm (10-12 Lb-Ft) (113-154 Lb-In) A/C Line Bracket Nuts ............................................................................................... .................................................................... 6.8-9.2 Nm (61-82 Lb-In) Outline Line to Auxiliary Evaporator Case Line ............................................................................................................................ 6.8-9.2 Nm (61-82 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Refrigerant Lines Hose/Line HVAC: Description and Operation Refrigerant Lines NOTE: Whenever a refrigerant line is replaced, it is also necessary to replace the suction accumulator/drier. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the following features: - the upstream side contains low pressure refrigerant gas. - the downstream side contains high pressure refrigerant gas. - an integral non-serviceable muffler and a serviceable high pressure A/C charge port valve are located on the downstream side. - the downstream side also contains a fitting used to mount the A/C pressure cut-off switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cut-off switch can be removed without discharging the A/C system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Refrigerant Lines > Page 8681 Hose/Line HVAC: Description and Operation Underbody A/C-Heater Lines Item Description 1 Green Tape 2 Front Auxiliary Heater Inlet Line 3 Blue Tape 4 Front Auxiliary Heater Inlet Line 5 White Tape (Bracket Locations) 6 Orange Tape 7 Front Auxiliary Heater Inlet Line 8 Rear Auxiliary Heater Outlet Line 9 Rear Auxiliary Evaporator Outlet Line 10 Rear Auxiliary Heater Inlet Line 11 Violet Tape 12 Rear Auxiliary Evaporator Outlet Line Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Refrigerant Lines > Page 8682 13 Front Auxiliary Heater Outlet Line 14 Red Tape 15 Rear Auxiliary Heater Inlet Line 16 Rear Auxiliary Heater Outlet Line 17 Rear Auxiliary Evaporator Outlet Line 18 Rear Auxiliary Evaporator Inlet Line 19 Yellow Tape 20 Rear Auxiliary Evaporator Inlet Line 21 Rear Auxiliary Evaporator Outlet Line 22 Rear Auxiliary Evaporator Outlet Line 23 Rear Auxiliary Evaporator Inlet Line 24 Rear Auxiliary Evaporator Inlet Line 25 Rear Auxiliary Heater Outlet Line 26 Rear Auxiliary Heater Inlet Line 27 Rear Auxiliary Heater Inlet Line 28 Rear Auxiliary Heater Outlet Line 29 Front Auxiliary Heater Outlet Line 30 Front Auxiliary Heater Outlet Line The auxiliary lines are one-piece tubes that are secured to the underbody of the vehicle. Replacement kits are only available with multiple-piece lines for ease of installation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil Hose/Line HVAC: Service and Repair Adding Refrigerant Oil 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 for replacement, 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 replacement part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. 1 Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 8685 4. For the A/C condenser core, add 30 ml (1 ounce) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when performing each of the following repairs: replacement of the A/C evaporator core orifice - replacement of the A/C compressor pressure relief valve - replacement of a refrigerant line - repair of an O-ring leak - repair of a charge port leak 6. Replacement of components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 8686 Hose/Line HVAC: Service and Repair Condenser To Evaporator Line REMOVAL 1. Disconnect the battery ground cable. 2. Recover the refrigerant. 3. Disconnect the condenser to evaporator line spring lock coupling from the A/C evaporator core. 4. Disconnect the A/C condenser core lower line. 1 Remove the nut. 2 Disconnect the A/C condenser core lower line. 5. Remove the tube bracket nut. 6. Remove the suction accumulator/drier bracket clamp bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 8687 7. Remove the evaporator to condenser tube. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring seal with Motorcraft YN-12b refrigerant oil F2AZ-19577-AB or equivalent meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 8688 Hose/Line HVAC: Service and Repair Front Auxiliary Evaporator Outlet and Inlet Line REMOVAL NOTE: The front auxiliary evaporator outlet line is shown, the front auxiliary evaporator inlet line is similar. 1. Recover the refrigerant from the system. 2. Turn the air suspension switch off, if equipped. 3. Raise and support the vehicle. 4. Remove the RH front fender splash shield. 1 Remove the bolts. 2 Remove the pushpins. 3 Remove the front fender splash shield. 5. Remove the three line brackets. 1 Remove the nuts. 2 Remove the bracket by inserting a screwdriver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 6. Disconnect the auxiliary outlet line from the condenser line. 1 Remove the nut. 2 Disconnect the line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 8689 7. Disconnect the front auxiliary outlet line from the rear auxiliary line. 1 Remove the nut. 2 Disconnect the line. 8. Remove the front auxiliary evaporator outlet line. INSTALLATION 1. Install the front auxiliary evaporator outlet line. 2. Connect the front auxiliary outlet line to the rear auxiliary line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 8690 3. Connect the front auxiliary outlet line to the condenser line. 1 Connect the line. 2 Install the nut. 4. Install the line brackets. 1 Position the bracket. 2 Install the nut. - Snap the line into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the line. 5. Install the front fender splash shield. 6. Lower the vehicle. 7. Turn on the air suspension switch, if equipped. 8. Evacuate and charge the A/C system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 8691 Hose/Line HVAC: Service and Repair Rear Auxiliary Evaporator Inlet Line REMOVAL 1. Discharge and recover the refrigerant. 2. Remove the quarter trim panel access cover. 3. Disconnect the inlet line from the underbody line. 1 Remove the nut. 2 Remove the line. 4. Remove the auxiliary A/C lines grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Remove the four line brackets. 1 Remove the nuts. 2 Remove the bracket by inserting a screwdriver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 8692 9. Disconnect the inlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. 10. Cut the (3/8 inch) inlet line in four places. 11. Remove and discard the cut sections. INSTALLATION 1. Install the inlet line from the rear of the vehicle over the frame. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 8693 2. Connect the inlet line to the front underbody A/C lines. 1 Connect the inlet line. 2 Loosely install the nut. 3. Install the inlet line over the frame. - Insert the end with the orange tape first. 4. Connect the two inlet lines. 1 Connect the inlet lines. 2 Loosely install the nut. 5. Install the inlet line. - Install the end with the yellow tape between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 8694 6. Connect the two inlet lines. - Connect the fitting and loosely install the nut. 7. Install the inlet line. - Install the end without tape through the floor. 8. Connect the inlet line to the inlet line. 1 Connect the line. 2 Loosely install the nut. 9. Tighten the four peanut fittings. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 8695 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. - Snap the line into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the line. 11. Lower the vehicle. 12. Turn on the air suspension switch, if equipped. 13. Connect the inlet line to the auxiliary evaporator case line. 14. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Install the quarter trim access panel. 16. Evacuate and charge the A/C system. 17. Install the spare tire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 8696 Hose/Line HVAC: Service and Repair Rear Auxiliary Evaporator Outlet Line REMOVAL 1. Discharge and recover the refrigerant. 2. Remove the quarter trim panel access cover. 3. Disconnect the outlet line from the underbody line. 1 Remove the nut. 2 Remove the line. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Remove the four line brackets. 1 Remove the nuts. 2 Remove the bracket by inserting a screwdriver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 8697 9. Disconnect the outlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. 10. Cut the outlet line in four places. 11. Remove and discard the cut sections. INSTALLATION 1. Install the outlet line over the frame. - Install the end with violet tape between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 8698 2. Connect the outlet line peanut fitting. 1 Connect the outlet lines. 2 Loosely install the nut. 3. Install the outlet line. - Install the end with the violet tape between the frame and body. 4. Connect the outlet line peanut fitting to the outlet line. 1 Connect the outlet lines. 2 Loosely install the nut. 5. Install the outlet line. - Install the end with the yellow tape over the frame. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 8699 6. Connect the outlet line peanut fitting to the outlet line. - Connect the fitting and loosely install the nut. 7. Install the outlet line. - Install the end with the orange tape between the frame and the body near the rear wheel opening. 8. Connect the outlet line peanut fitting to the outlet line. - Connect the fitting and loosely install the nut. 9. Install the outlet line. - Install the end of the tube with no tape through the floor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 8700 10. Connect the outlet line peanut fitting to outlet line. - Connect the fitting and loosely install the nut. 11. Tighten the five peanut fittings. 12. Install the line brackets. 1 Position the bracket. 2 Install the nut. - Snap the line into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the line. 13. Lower the vehicle. 14. Turn the air suspension switch on, if equipped. 15. Connect the outlet line to the auxiliary evaporator case line. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Adding Refrigerant Oil > Page 8701 16. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 17. Install the quarter trim access panel. 18. Evacuate and charge the A/C system. 19. Install the spare tire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Page 8702 Hose/Line HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8707 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8708 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8709 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8710 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8711 Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8712 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8713 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8714 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity With Aux Air ......................................................................................................................................... .................................................................... 62.0 oz. With our Aux Air ................................................ ...................................................................................................................................................... 37.0 oz. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 8717 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ..................................................................... R-134a* *Meeting Ford Specification WSH-M17B19-A Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 8722 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 8723 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 8724 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Capacity Without Auxiliary .................................................................................................................................. ...................................................... 266 ml (9 oz) With Auxiliary .......................................................... ................................................................................................................................. 414 ml (14 oz) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 8729 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type ....................................................................................................................................................... Motorcraft YN-12b or Equivalent* *In Canada, CYN-12b. Oil must meet Ford Specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair > Compressor Oil Refrigerant Oil: Service and Repair Compressor Oil Adding Refrigerant Oil 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 for replacement, 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 replacement part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. 1 Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair > Compressor Oil > Page 8732 4. For the A/C condenser core, add 30 ml (1 ounce) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when performing each of the following repairs: replacement of the A/C evaporator core orifice - replacement of the A/C compressor pressure relief valve - replacement of a refrigerant line - repair of an O-ring leak - repair of a charge port leak 6. Replacement of components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Refrigerant Oil Addition 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 for replacement, 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 replacement part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor NOTE: Service A/C compressors are shipped without compressor oil. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair > Compressor Oil > Page 8733 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. 1 Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. 4. For the A/C condenser core, add 30 ml (1 ounce) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when performing each of the following repairs: replacement of the A/C evaporator core orifice - replacement of the A/C compressor pressure relief valve - replacement of a refrigerant line - repair of an O-ring leak - repair of a charge port leak 6. Replacement of components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair > Compressor Oil > Page 8734 Refrigerant Oil: Service and Repair Refrigerant Oil 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 for replacement, 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 replacement part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. 1 Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair > Compressor Oil > Page 8735 4. For the A/C condenser core, add 30 ml (1 ounce) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean Motorcraft YN-12b refrigerant oil F2AZ-19577-AC (Canada: Motorcraft CYN-12b) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when performing each of the following repairs: replacement of the A/C evaporator core orifice - replacement of the A/C compressor pressure relief valve - replacement of a refrigerant line - repair of an O-ring leak - repair of a charge port leak 6. Replacement of components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications A/C Cycling Switch .............................................................................................................................. .......................................... 1.4-3.8 Nm (12-33 Lb-In) Pressure Cut Off Switch ............................................................................................................................................................. 6.8-13.6 Nm (61-121 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 8740 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Cycling Switch Closes .................................................................................................................. ......................................................... 324 kPa (47 psi) A/C Cycling Switch Opens ............................. .............................................................................................................................................. 152 kPa (22 psi) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch Typical Air Conditioning Pressure Sensor The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1724 kPa (250 psi) the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 8743 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). - The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). - When the A/C cycling switch contacts close, the A/C clutch field coil is energized. - When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the A/C cycling pressure switch electrical connector. 2. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring seal with Motorcraft YN-12b refrigerant oil F2AZ-19577-AB or equivalent meeting Ford specification WSH-M1C231-B. 2. Perform refrigerant system Leak Detection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 8746 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the electrical connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. Follow the removal procedure in reverse order. 1 Lubricate the O-ring seal with Motorcraft YN-12b refrigerant oil F2AZ-19577-AB or equivalent meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 8751 Blower/Flasher Relay Block The Blower Relay is located in the blower/flasher relay block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations As shown in the wiring diagrams, these vehicles do not use a compressor cut-off (also called a wide open throttle or WOT) relay. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control Control Module HVAC: Description and Operation Blower Motor Speed Control The A/C blower motor speed control is a Pulse Width Modulated (PWM) type which provides variable blower speed control of the blower motor. The A/C blower motor speed control is controlled by switching the control signal voltage of 5 volts OFF and ON 2,000 times per second. By varying the ratio of time on (+5 volts) to time off (0 volts), the EATC module tells the A/C blower motor speed control how fast the blower motor should run. The A/C blower motor speed control has the following features: - Controls the speed of the blower motor by switching the motor OFF and ON 40,000 times per second by varying the ratio of time ON (+14 volts) to time OFF (0 volts). - Has circuitry to protect the blower motor from burning out in the event of a locked rotor condition. - Can compensate for changes in battery positive voltage (B+) which prevents the blower speed from slowing down when the engine is idling and will provide up to a maximum of 30 amperes for blower motor operation with battery voltages between 10 and 16 volts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control > Page 8759 Control Module HVAC: Description and Operation Electronic Climate Control Module The Electronic Automatic Temperature Control (EATC) module, located in the instrument panel, has the following features: - 11 push buttons - a blower speed override thumbwheel for manual input - a vacuum fluorescent display for displaying set temperature, ambient temperature, function and Diagnostic Trouble Codes (DTCs) - an On-Board Diagnostic (OBD) feature to supply the technician with Diagnostic Trouble Codes (DTCs). These DTCs direct the technician to the inoperative component. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control Control Module HVAC: Service and Repair Blower Motor Speed Control REMOVAL 1. Disengage the stops and lower the glove compartment door. 2. Disengage the blower motor speed control mounting bracket from the instrument panel. 3. Disconnect the connectors. 4. Disengage the retaining tabs and remove the blower motor speed control from the mounting bracket. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 8762 Control Module HVAC: Service and Repair Electronic Climate Control Module REMOVAL 1. Disconnect the battery ground cable. 2. Remove the center instrument panel finish panel. - Carefully pry to release the four clips. 3. Disconnect the control switch connector. 4. Remove the screws from the electronic automatic temperature control module. 5. Remove the electronic automatic temperature control module. 1 Disconnect the electrical connectors. 2 Remove the nuts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 8763 3 Disconnect the vacuum harness connector and remove the EATC module. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 8764 Control Module HVAC: Service and Repair Illumination Bulbs REMOVAL 1. Remove the control assembly. 2. Unsnap the bezel and pivot it open. - To replace the general illumination bulbs, unscrew the lamp holders and remove the bulb. - To replace the HI/LO bulb, cut the wires close to the bulb base, splice the wires to the new bulb and wrap the splice with electrical tape. NOTE: Place the module upside-down on a non-marring surface. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC Air Door Position Sensor / Switch: Diagrams Air Door Position Sensor / Switch, HVAC Front Mode Potentiometer Rear Mode Potentiometer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC > Page 8770 Air Door Position Sensor / Switch: Diagrams Blend Door Position Sensor Front Blend Potentiometer Rear Blend Potentiometer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation Ambient Temperature Sensor / Switch HVAC: Description and Operation The A/C ambient air temperature sensor and bracket: - is located in front of the A/C condenser core near the center of the vehicle. - contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the electronic automatic temperature control assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch Blower Motor Switch: Diagrams Blower Switch Front Blower Motor Switch Rear Blower Motor Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 8778 Rear Integrated Control Panel (Rear Blower Switch) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 8779 Blower Motor Switch: Diagrams Blower Switch Illumination Front Blower Switch Illumination Rear Blower Switch Illumination Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch Blower Motor Switch: Testing and Inspection Blower Switch Blower Motor Switch - Component Testing Procedure Blower Motor Switch - Terminal Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 8782 Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 8783 Blower Motor Switch: Testing and Inspection Front Blower Switch Front Blower Motor Switch - Component Testing Procedure Front Blower Motor Switch - Terminal Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 8784 Front Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 8785 Blower Motor Switch: Testing and Inspection Rear Auxiliary Rear Blower Motor Switch - Component Testing Procedure Rear Blower Motor Switch - Terminal Locations Rear Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Specifications Cabin Temperature Sensor / Switch: Specifications In-Car Temperature Sensor Screws ...................................................................................................................................................... 2-3 Nm (18-27 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Specifications > Page 8789 Cabin Temperature Sensor / Switch: Description and Operation The in-car temperature sensor operates in the following manner: - A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. - An automatic temperature control sensor hose and elbow is connected between the plenum assembly and the in-car temperature sensor. - The automatic temperature control sensor hose and elbow uses air from the plenum assembly air stream to create a suction at the in-car temperature sensor. - The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Specifications > Page 8790 Cabin Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the center instrument panel finish panel. 1 Carefully pry to release the four clips. 2. Disconnect the control switch connector. 3. Remove the screws and the accessory outlet trim panel. 4. Remove the screws. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Specifications > Page 8791 5. Disconnect the electrical connector and remove the sensor from the hose. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications A/C Cycling Switch .............................................................................................................................. .......................................... 1.4-3.8 Nm (12-33 Lb-In) Pressure Cut Off Switch ............................................................................................................................................................. 6.8-13.6 Nm (61-121 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 8796 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Cycling Switch Closes .................................................................................................................. ......................................................... 324 kPa (47 psi) A/C Cycling Switch Opens ............................. .............................................................................................................................................. 152 kPa (22 psi) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch Typical Air Conditioning Pressure Sensor The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1724 kPa (250 psi) the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 8799 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). - The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). - When the A/C cycling switch contacts close, the A/C clutch field coil is energized. - When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the A/C cycling pressure switch electrical connector. 2. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring seal with Motorcraft YN-12b refrigerant oil F2AZ-19577-AB or equivalent meeting Ford specification WSH-M1C231-B. 2. Perform refrigerant system Leak Detection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 8802 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the electrical connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. Follow the removal procedure in reverse order. 1 Lubricate the O-ring seal with Motorcraft YN-12b refrigerant oil F2AZ-19577-AB or equivalent meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation Solar Sensor: Description and Operation The A/C sunload sensor: - is located on the top of the instrument panel. - contains a photovoltaic diode that is sensitive to light. - has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Page 8806 Solar Sensor: Service and Repair REMOVAL 1. Remove the instrument panel upper finish panel. 2. Disconnect the connector. 3. Remove the A/C sunload sensor from the instrument panel upper finish panel. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation Service Gauge Port Valve The high-pressure service gauge port valve is located on the A/C manifold and tube. The low pressure service gauge port valve is located on the suction accumulator/drier. The fitting is an integral part of the refrigeration line or component. - Special couplings are required for both the high side and low side service gauge ports. - The Schrader-type valve core can be replaced if the seal leaks. - Always install the A/C charging valve cap on the service gauge port valves after repairing the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and Operation Solar Sensor: Description and Operation The A/C sunload sensor: - is located on the top of the instrument panel. - contains a photovoltaic diode that is sensitive to light. - has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and Operation > Page 8813 Solar Sensor: Service and Repair REMOVAL 1. Remove the instrument panel upper finish panel. 2. Disconnect the connector. 3. Remove the A/C sunload sensor from the instrument panel upper finish panel. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and Repair Vacuum Harness HVAC: Service and Repair Vacuum Tester Kit SPECIAL TOOL(S) 1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of standard 3-mm (0.125-inch) inner diameter vacuum hose approximately 25 mm (1 inch longer than the damaged area of the mini-tube vacuum hose. 3. Cut off the mini-tube vacuum hose on each side of the damaged area. 4. Dip the mini-tube hose ends in commercially available paint thinner containing Methyl Ethyl Ketone (MEK). This solvent will seal the mini-tube in the vacuum hose. WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL. 5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (0.375 inch) into the ends of the standard 3-mm (0.125-inch) service vacuum hose section. 6. Shake the service joint after assembly to ensure 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 Tester or equivalent. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and Repair > Page 8817 Vacuum Tester Kit Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service and Repair Vacuum Reservoir HVAC: Service and Repair REMOVAL 1. Remove the battery and battery tray. 2. Disconnect the A/C vacuum tank hose for the A/C vacuum reservoir tank and bracket. 3. Remove the screw and the A/C vacuum reservoir tank and bracket. INSTALLATION 1. Follow the removal procedure in reverse order. NOTE: When positioning the A/C vacuum reservoir tank, make sure that the bottom locator and two top tabs align with the battery tray. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Wiring Harness HVAC > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness HVAC: > 98-23-9 > Nov > 98 > A/C - No/Intermittent Auxiliary A/C Mode/Blower Control Wiring Harness HVAC: Customer Interest A/C - No/Intermittent Auxiliary A/C Mode/Blower Control Article No. 98-23-9 11/23/98 AIR CONDITIONING - NO OR INTERMITTENT AUXILIARY A/C MODE BLOWER CONTROL VEHICLES BUILT THROUGH 9/8/98 LIGHT TRUCK: 1997-98 EXPEDITION 1998 NAVIGATOR ISSUE There may be no or intermittent auxiliary A/C mode/blower control on some vehicles. This may be caused by the -14335- wire harness being cut on the rail edge in the headliner. ACTION Repair harness and install 9 mm (3/8") convolute to protect harness. The convolute should protect the wire harness from being cut on the rail edge. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify concern. 2. Gain access to the -14335- wire harness by removing the left side rear passenger rail edge moulding and assist handle and lowering the headliner. 3. Repair wire harness. 4. Wrap harness with a 12.7cm (5") long piece of 9 mm (27/64") Convolute Wire Shield (D4SZ-14A099-F 25-Ft Bulk). 5. Reinstall rail edge moulding. 6. Verify repair. PART NUMBER PART NAME D4SZ-14A099-F Wire Shield - 27/64" (25-Ft Bulk - Only 5" Is Required) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982309A Repair Wire Harness 0.6 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 14335 B4 OASIS CODES: 203000, 208000, 208100, 208200, 208300, 208999 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Wiring Harness HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness HVAC: > 98-23-9 > Nov > 98 > A/C - No/Intermittent Auxiliary A/C Mode/Blower Control Wiring Harness HVAC: All Technical Service Bulletins A/C - No/Intermittent Auxiliary A/C Mode/Blower Control Article No. 98-23-9 11/23/98 AIR CONDITIONING - NO OR INTERMITTENT AUXILIARY A/C MODE BLOWER CONTROL VEHICLES BUILT THROUGH 9/8/98 LIGHT TRUCK: 1997-98 EXPEDITION 1998 NAVIGATOR ISSUE There may be no or intermittent auxiliary A/C mode/blower control on some vehicles. This may be caused by the -14335- wire harness being cut on the rail edge in the headliner. ACTION Repair harness and install 9 mm (3/8") convolute to protect harness. The convolute should protect the wire harness from being cut on the rail edge. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify concern. 2. Gain access to the -14335- wire harness by removing the left side rear passenger rail edge moulding and assist handle and lowering the headliner. 3. Repair wire harness. 4. Wrap harness with a 12.7cm (5") long piece of 9 mm (27/64") Convolute Wire Shield (D4SZ-14A099-F 25-Ft Bulk). 5. Reinstall rail edge moulding. 6. Verify repair. PART NUMBER PART NAME D4SZ-14A099-F Wire Shield - 27/64" (25-Ft Bulk - Only 5" Is Required) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982309A Repair Wire Harness 0.6 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 14335 B4 OASIS CODES: 203000, 208000, 208100, 208200, 208300, 208999 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect the battery ground cable. WARNING: THE BACKUP POWER SUPPLY ENERGY MUST BE DEPLETED BEFORE ANY AIR BAG COMPONENT REPAIR IS PERFORMED. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the driver side air bag module from the vehicle. WARNING: PLACE THE AIR BAG MODULE ON A BENCH WITH THE TRIM COVER FACING UP TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 4. Connect the air bag simulator to the vehicle harness at the top of the steering column. 5. Remove the passenger side air bag module from the vehicle. WARNING: PLACE THE AIR BAG MODULE ON A BENCH WITH THE DEPLOYMENT DOOR FACING UP TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 6. Connect the air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Reactivation Procedure 1. Disconnect the battery ground cable. WARNING: THE AIR BAG SIMULATORS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. In stall the driver side air bag module. 5. Remove the air bag simulator from the vehicle harness connector at the passenger side air bag module. 6. Install the passenger side air bag module. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 8. Prove out the system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8840 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Are both air bag sensors connected and mounted to the vehicle? [ ] 2. Is the three-way connector at the base of the steering column connected? [ ] 3. Are the air bag modules or air bag simulators connected? [ ] 4. Is the air bag diagnostic monitor connected? [ ] 5. Is the vehicle battery connected? [ ] Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Specifications Air Bag: Specifications Driver Side Air Bag Module Screws ............................................................................................................................................. 9-12 N.m (79-106 Lb/In) Passenger Side Air Bag Module Screws ................................................................................................................................... 7-6-10.4 N.m (67-92 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Side Air Bag Module Air Bag: Description and Operation Driver Side Air Bag Module Driver Air Bag Module The driver side air bag module: ^ is replaced as an assembly. ^ is mounted in the center of the steering wheel. Steering Wheel Trim Cover The steering wheel trim cover: ^ encases the driver side air bag module and horn switch. ^ has tear seams that separate to allow inflation of the air bag. ^ must not be repainted for any reason. ^ is a component of the driver side air bag module and is not repaired separately. Air Bag The air bag: ^ is constructed of nylon. ^ is a component of the driver side air bag module and is not replaced separately. Inflator The inflator: ^ receives electrical energy when the air bag sensors close. ^ contains an igniter that converts the electrical signal to thermal energy (heat), causing the ignition of the inflator gas generant. ^ inflates the air bag with nitrogen gas after the chemical reaction takes place. ^ is a component of the driver side air bag module and is not replaced separately. Mounting Plate and Retainer Ring The mounting plate and retainer ring: ^ attach and seal the air bag to the inflator. ^ attach the trim cover. ^ mount the entire driver side air bag module to the steering wheel. ^ are components of the driver side air bag module and are not replaced separately. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Side Air Bag Module > Page 8846 Air Bag: Description and Operation Passenger Side Air Bag Module The passenger side air bag module: ^ is replaced as an assembly. ^ is mounted in the RH side of the instrument panel. Deployment Door The deployment door: ^ is textured and painted to match the surface of the instrument panel. ^ has a tear seam that separates when the air bag inflates, and hinges out of the way during deployment. ^ retains the air bag in the reaction housing until deployment. ^ must not be repainted for any reason. ^ is a component of the passenger side air bag module and is not replaced separately. Air Bag The air bag: ^ is constructed of nylon. ^ is a component of the passenger side air bag module and is not replaced separately. Inflator The inflator: ^ receives electrical energy when the air bag sensors close. ^ contains an igniter that converts the electrical signal to thermal energy (heat), causing the ignition of the inflator gas generant. ^ inflates the air bag with argon after the chemical reaction takes place. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Side Air Bag Module > Page 8847 ^ is a component of the passenger side air bag module and is not replaced separately. Reaction Housing The reaction housing: ^ provides support for the inflator. ^ provides a reaction surface for the passenger side air bag module. ^ is used to attach the deployment door. ^ contains mounting brackets that attach the passenger side air bag module to the instrument panel. ^ is a component of the passenger side air bag module and is not replaced separately. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures Air Bag: Service and Repair Air Bag Disposal Procedures Deployed Air Bag WARNING: ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. 1. Dispose of the deployed air bag modules in the same manner as any other part to be scrapped. Inoperative NOTE: All inoperative air bag modules have been placed on the Mandatory Return List. All discolored or damaged air bag modules should be treated the same as any inoperative live air bag being returned. 1. Remove the inoperative driver side air bag module or passenger side air bag module. NOTE: When replacing an air bag module, a prepaid return postcard is provided with the replacement air bag module. The serial number for the new part and the Vehicle Identification Number (VIN) must be recorded and sent to Ford Motor Company. 2. When replacing the driver side air bag module, record the necessary information and return the inoperative driver side air bag module to Ford Motor Company. 3. When replacing the passenger side air bag module, record the necessary information and return the inoperative passenger side air bag module to Ford Motor Company. Scrapped Vehicle Remote Deployment WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER OR DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH A MINIMAL CHANCE OF INJURY. ^ REMOTE DEPLOYMENT IS TO BE PERFORMED OUTDOORS WITH ALL PERSONNEL AT LEAST 6.1 METERS (20 FEET) AWAY TO ENSURE PERSONAL SAFETY AND DUE TO THE LOUD REPORT WHICH OCCURS WHEN THE Am BAG IS DEPLOYED. ^ DO NOT PLACE THE DRIVER OR PASSENGER SIDE AIR BAG MODULE WITH THE TRIM COVER OR DEPLOYMENT DOOR FACING DOWN, AS THE FORCES OF THE DEPLOYING AIR BAG CAN CAUSE IT TO RICOCHET AND CAUSE PERSONAL Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures > Page 8850 INJURY. NOTE: The passenger side air bag module is shown; the driver side air bag module is similar. 1. Remove the passenger side air bag module. 2. Cut the two connector wires on the passenger side air bag module, and strip 25 mm (1 inch) of insulation from the ends of the wires. 3. Obtain two wires at least 6.1 meters (20 feet) long and connect one end of each wire to each of the wires on the passenger side air bag module. 4. Place the passenger side air bag module on a flat surface with the deployment door facing upward in an open outdoor area. 5. Remain at least 6.1 meters (20 feet) away from the passenger side air bag module. 6. Deploy the air bag by touching the other ends of the two wires to the terminals of a 12-volt battery. 7. Allow at least ten minutes before approaching the deployed air bag to allow for cooling. 8. Dispose of the deployed air bag module in the same manner as any other part to be scrapped. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures > Page 8851 Air Bag: Service and Repair Removal and Installation Driver's Side REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH A MINIMAL CHANCE OF INJURY. ^ PLACE A LIVE AIR BAG MODULE ON A BENCH OR OTHER SURFACE WITH THE TRIM COVER UP. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE REPLACED, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. NOTE: A repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable. 2. Remove the driver side air bag module. 1. Remove the two back cover plugs. 2. Remove the two driver side air bag module screws. 3. Disconnect the horn electrical connector. 4. Disconnect the air bag sliding contact electrical connector. 5. Remove the driver side air bag module. 3. If the driver side air bag module is diagnosed as faulty, dispose of the air bag. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures > Page 8852 1. Follow the removal procedure in reverse order. WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH A MINIMAL CHANCE OF INJURY. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: A repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Passenger's Side REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH A MINIMAL CHANCE OF INJURY. ^ PLACE A LIVE AIR BAG MODULE ON A BENCH OR OTHER SURFACE WITH THE DEPLOYMENT DOOR UP ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE REPLACED, NOT REPAINTED. ^ 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. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. NOTE: A repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures > Page 8853 2. Remove the instrument panel relay cover. 3. Remove the passenger side air bag module. 1. Remove the screws. 2. Disconnect the electrical connector. 3. Remove the passenger side air bag module. 4. If the passenger side air bag module is diagnosed as faulty, dispose of the air bag. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH A MINIMAL CHANCE OF INJURY. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: A repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its adaptive strategy The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Air Bag Diagnostic Monitor Screws ..................................................................................................................................... 10.2-13.8 N.m (90-122 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 8857 Air Bag Control Module: Locations Instrument Panel View The Air Bag Diagnostic Monitor is located behind right side (Passenger Side) of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 8858 Air Bag Control Module: Diagrams Air Bag Diagnostic Monitor (C208) Air Bag Diagnostic Monitor (C209) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 8859 Air Bag Control Module: Description and Operation WARNING: UNDER NO CIRCUMSTANCES SUBSTITUTE ANOTHER FUSE VALUE FOR THE 10 A BATTERY FUSE. ANY FUSE OTHER THAN 10 A CAN CAUSE DISARMING FAILURE AND CAN RESULT IN DANGER TO THE OCCUPANTS OF THE VEHICLE. DO NOT ATTEMPT TO REPLACE THE 10 A BATTERY FUSE UNTIL THE AIR BAG SYSTEM FIRST HAS BEEN DEACTIVATED. REFER TO DEACTIVATION PROCEDURE. See: Air Bag(s) Arming and Disarming/Service and Repair/Arming and Disarming NOTE: The safing sensor is internal to the air bag diagnostic monitor and is not replaced separately. The air bag diagnostic monitor continually monitors all air bag Supplemental Restraint System (SRS) components and wiring connections for possible faults in the system. If the air bag diagnostic monitor detects a fault in the SRS when the ignition switch is in the RUN position, a Lamp Fault Code (LFC) will be displayed by the air bag indicator, located on the instrument cluster. The air bag diagnostic monitor does not deploy the air bag in the event of a collision. The LH or RH air bag sensor and the safing sensor determine when to deploy the air bag. The air bag diagnostic monitor illuminates the air bag indicator for approximately six seconds when the ignition switch is in the RUN position and then turns the indicator off. This shows that the air bag indicator is operational. If the air bag indicator does not illuminate or the indicator stays on or flashes at any time, a fault has been detected by the air bag diagnostic monitor. LFCs may not be displayed for approximately 30 seconds after the ignition switch is placed in the RUN position. This is the amount of time the air bag diagnostic monitor requires to perform all tests and verify system faults. Each LFC (a series of flashes and pauses of the air bag indicator): ^ represents a two-digit number. ^ is always displayed at least twice. If the air bag diagnostic monitor detects a fault in the SRS, a Diagnostic Trouble Code (DTC) will be written to the air bag diagnostic monitor non-volatile RAM (NVRAM). This DTC will then cause the air bag diagnostic monitor to flash an LFC on the air bag indicator. DTCs can be retrieved with the New Generation Star (NGS) Tester. After repair, the DTC can then be cleared from the NVRAM. If a system fault is present and the air bag indicator is malfunctioning, an audible chime will be heard. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS requires repair. If a fault exists that makes unwanted air bag deployment possible, the air bag diagnostic monitor will attempt to remove deployment power by turning on a solid state switch to blow the 10 A battery Fuse 2. If the 10 A battery fuse has successfully been blown by the air bag diagnostic monitor, the air bag diagnostic monitor will not attempt to blow it again until the proper fault has been repaired and cleared. The air bag diagnostic monitor will store both the unwanted deployment DTC and the loss of deployment power DTC. The loss of deployment power DTC is the highest priority. DTCs are prioritized numerically. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. The air bag diagnostic monitor includes an internal backup power supply. This feature provides sufficient backup power to deploy the air bag in the event the battery or battery cables are damaged in a collision before safing and air bag sensors close. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 8860 Air Bag Control Module: Service and Repair REMOVAL WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: The safing sensor is internal to the air bag diagnostic monitor and is not replaced separately. 1. Disconnect the battery ground cable. 2. Remove the RH cowl side trim panel. 3. Remove the air bag diagnostic monitor 1. Disconnect the two electrical connectors. 2. Remove the screws. 3. Remove the air bag diagnostic monitor. INSTALLATION 1. Follow the removal procedure in reverse order. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clock Spring Assembly Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 8864 Clockspring Assembly / Spiral Cable: Description and Operation The air bag sliding contact: ^ is mounted on the steering column tube, behind the steering wheel. ^ continuously transfers electrical signals from the driver side air bag module to the air bag sensors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 8865 Clockspring Assembly / Spiral Cable: Service and Repair REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH A MINIMAL CHANCE OF INJURY. ^ PLACE A LIVE AIR BAG MODULE ON A BENCH OR OTHER SURFACE WITH THE TRIM COVER UP. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE REPLACED, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. NOTE: A repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Remove the driver side air bag module. 2. Remove the steering wheel. NOTE: Make sure the wheels are in the straight-ahead position. 3. Twist the tilt wheel handle and shank and remove. 4. Remove the lower steering column shroud. 1. Remove the screws. 2. Remove the steering column shroud. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 8866 5. Remove the ignition switch lock cylinder. 1. Position the lock cylinder to RUN. 2. Using a suitable tool, push upward on the cylinder release tab through the hole in the lower shroud while pulling the cylinder outward. 6. Carefully pry to release the clips and remove the steering column opening cover. 7. Remove the upper steering column shroud. 8. Prevent accidental rotation of the air bag sliding contact. 1. Check to see if the service lock is missing. 2. If the service lock is missing, apply two strips of masking tape across the air bag sliding contact. NOTE: The air bag sliding contact has a service lock that prevents accidental rotation when the steering wheel is removed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 8867 9. Remove the key-in ignition warning indicator switch. 10. Disconnect the air bag sliding contact electrical connector and separate the air bag electrical connector from the bracket. 11. Pry the retaining clips loose. 12. Separate the wire from the two retaining clips holding wire to the column. 13. Remove the air bag sliding contact ^ Feed the wiring harness through the instrument panel. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH A MINIMAL CHANCE OF INJURY. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: A repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 1. If the lock is missing, realign the air bag sliding contact. 1. Rotate the air bag sliding contact rotor counterclockwise until it stops. 2. Rotate two revolutions Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 8868 3. Install per instructions. NOTE: The air bag sliding contact has a service lock that prevents rotation of the air bag sliding contact when the steering wheel is removed. 2. Properly orientate the air bag sliding contact. 1. The air bag electrical pigtail must point to the three o'clock position. 2. The dot on the steering shaft must be at the nine o'clock position. 3. Press at six, twelve, and three o'clock positions to seat the air bag sliding contact. 4. Rotate the wiring and secure into two wire clips. 5. Connect the two electrical connectors. Snap into the bracket. 6. Install the key-in ignition warning indicator switch. 7. If a new clock spring is used, remove the yellow anti-rotation tab. 8. Install the ignition switch lock cylinder. 1. Turn the ignition switch lock cylinder to the RUN position. 2. Insert the ignition switch lock cylinder into the steering column housing. 3. Make sure the ignition switch lock cylinder is fully seated and aligned in the interlocking washer before turning the key to the OFF position. This will permit the retaining pin of the ignition switch lock cylinder to extend into the hole in the steering column. 9. Rotate the ignition switch lock cylinder, using the key, to make sure of correct mechanical operation in all positions. 10. Install the upper and lower steering column shrouds. 11. Install the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 8869 12. Install the tilt wheel handle and shank. 13 Install the steering wheel. NOTE: Make sure the front wheels are in the straight-ahead position. 14. Install the driver side air bag module. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Air Bag Sensor Screws .......................................................................................................................................................... 10.2-13.8 N.m (90-122 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Primary Crash Sensor Impact Sensor: Locations Left Front Primary Crash Sensor Engine View The Left Primary Crash Sensor is located at the left front of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Primary Crash Sensor > Page 8875 Impact Sensor: Locations Right Primary Crash Sensor Engine View The Right Primary Crash Sensor is located at the right front of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 8876 Impact Sensor: Description and Operation WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION WHERE THE RADIATOR GRILLE OPENING PANEL, FRAME RAILS, OR COWL PANELS HAVE BEEN DAMAGED, INSPECT THE SENSOR MOUNTING BRACKETS FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAGS ARE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE SENSOR MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. NOTE: Undamaged air bag sensors will reset automatically after a collision and can be reused. The air bag Supplemental Restraint System (SRS) contains the following three sensors. ^ LH air bag sensor and bracket. ^ RH air bag sensor and bracket. ^ Safing sensor that is internal to the air bag diagnostic monitor. At least two sensors (one air bag sensor and the safing sensor) must be closed to inflate the air bag. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 8877 Impact Sensor: Service and Repair 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. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. NOTE: A repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable. 2. Remove the radiator air deflector. 1. Remove the push clips. 2. Remove the radiator air deflector 3. Disconnect the air bag sensor electrical connector (RH shown, LH similar). 4. Remove the air bag sensor. 1. Remove the screws. 2. Remove the air bag sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 8878 INSTALLATION WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED. NOTE: A repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Follow the removal procedure in reverse order. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Safing Sensor, Air Bag > Component Information > Description and Operation Safing Sensor: Description and Operation WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION WHERE THE RADIATOR GRILLE OPENING PANEL, FRAME RAILS, OR COWL PANELS HAVE BEEN DAMAGED, INSPECT THE SENSOR MOUNTING BRACKETS FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAGS ARE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE SENSOR MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. NOTE: Undamaged air bag sensors will reset automatically after a collision and can be reused. The air bag Supplemental Restraint System (SRS) contains the following three sensors. ^ LH air bag sensor and bracket. ^ RH air bag sensor and bracket. ^ Safing sensor that is internal to the air bag diagnostic monitor. At least two sensors (one air bag sensor and the safing sensor) must be closed to inflate the air bag. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Driver Side Air Bag Module Side Air Bag: Description and Operation Driver Side Air Bag Module Driver Air Bag Module The driver side air bag module: ^ is replaced as an assembly. ^ is mounted in the center of the steering wheel. Steering Wheel Trim Cover The steering wheel trim cover: ^ encases the driver side air bag module and horn switch. ^ has tear seams that separate to allow inflation of the air bag. ^ must not be repainted for any reason. ^ is a component of the driver side air bag module and is not repaired separately. Air Bag The air bag: ^ is constructed of nylon. ^ is a component of the driver side air bag module and is not replaced separately. Inflator The inflator: ^ receives electrical energy when the air bag sensors close. ^ contains an igniter that converts the electrical signal to thermal energy (heat), causing the ignition of the inflator gas generant. ^ inflates the air bag with nitrogen gas after the chemical reaction takes place. ^ is a component of the driver side air bag module and is not replaced separately. Mounting Plate and Retainer Ring The mounting plate and retainer ring: ^ attach and seal the air bag to the inflator. ^ attach the trim cover. ^ mount the entire driver side air bag module to the steering wheel. ^ are components of the driver side air bag module and are not replaced separately. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Driver Side Air Bag Module > Page 8886 Side Air Bag: Description and Operation Passenger Side Air Bag Module The passenger side air bag module: ^ is replaced as an assembly. ^ is mounted in the RH side of the instrument panel. Deployment Door The deployment door: ^ is textured and painted to match the surface of the instrument panel. ^ has a tear seam that separates when the air bag inflates, and hinges out of the way during deployment. ^ retains the air bag in the reaction housing until deployment. ^ must not be repainted for any reason. ^ is a component of the passenger side air bag module and is not replaced separately. Air Bag The air bag: ^ is constructed of nylon. ^ is a component of the passenger side air bag module and is not replaced separately. Inflator The inflator: ^ receives electrical energy when the air bag sensors close. ^ contains an igniter that converts the electrical signal to thermal energy (heat), causing the ignition of the inflator gas generant. ^ inflates the air bag with argon after the chemical reaction takes place. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Driver Side Air Bag Module > Page 8887 ^ is a component of the passenger side air bag module and is not replaced separately. Reaction Housing The reaction housing: ^ provides support for the inflator. ^ provides a reaction surface for the passenger side air bag module. ^ is used to attach the deployment door. ^ contains mounting brackets that attach the passenger side air bag module to the instrument panel. ^ is a component of the passenger side air bag module and is not replaced separately. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module Side Air Bag: Service and Repair Driver Side Air Bag Module REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH A MINIMAL CHANCE OF INJURY. ^ PLACE A LIVE AIR BAG MODULE ON A BENCH OR OTHER SURFACE WITH THE TRIM COVER UP. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE REPLACED, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. NOTE: A repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable. 2. Remove the driver side air bag module. 1. Remove the two back cover plugs. 2. Remove the two driver side air bag module screws. 3. Disconnect the horn electrical connector. 4. Disconnect the air bag sliding contact electrical connector. 5. Remove the driver side air bag module. 3. If the driver side air bag module is diagnosed as faulty, dispose of the air bag. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 8890 WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH A MINIMAL CHANCE OF INJURY. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: A repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 8891 Side Air Bag: Service and Repair Passenger Side Air Bag REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH A MINIMAL CHANCE OF INJURY. ^ PLACE A LIVE AIR BAG MODULE ON A BENCH OR OTHER SURFACE WITH THE DEPLOYMENT DOOR UP ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE REPLACED, NOT REPAINTED. ^ 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. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. NOTE: A repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable. 2. Remove the instrument panel relay cover. 3. Remove the passenger side air bag module. 1. Remove the screws. 2. Disconnect the electrical connector. 3. Remove the passenger side air bag module. 4. If the passenger side air bag module is diagnosed as faulty, dispose of the air bag. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 8892 WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH A MINIMAL CHANCE OF INJURY. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: A repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its adaptive strategy The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Standby Power Supply, Air Bag > Component Information > Description and Operation Standby Power Supply: Description and Operation The air bag diagnostic monitor includes an internal backup power supply. This feature provides sufficient backup power to deploy the air bag in the event the battery or battery cables are damaged in a collision before safing and air bag sensors close. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Testing and Inspection Malfunction Lamp / Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Air Bag Diagnostic Monitor Screws ..................................................................................................................................... 10.2-13.8 N.m (90-122 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 8903 Air Bag Control Module: Locations Instrument Panel View The Air Bag Diagnostic Monitor is located behind right side (Passenger Side) of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 8904 Air Bag Control Module: Diagrams Air Bag Diagnostic Monitor (C208) Air Bag Diagnostic Monitor (C209) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 8905 Air Bag Control Module: Description and Operation WARNING: UNDER NO CIRCUMSTANCES SUBSTITUTE ANOTHER FUSE VALUE FOR THE 10 A BATTERY FUSE. ANY FUSE OTHER THAN 10 A CAN CAUSE DISARMING FAILURE AND CAN RESULT IN DANGER TO THE OCCUPANTS OF THE VEHICLE. DO NOT ATTEMPT TO REPLACE THE 10 A BATTERY FUSE UNTIL THE AIR BAG SYSTEM FIRST HAS BEEN DEACTIVATED. REFER TO DEACTIVATION PROCEDURE. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Arming and Disarming NOTE: The safing sensor is internal to the air bag diagnostic monitor and is not replaced separately. The air bag diagnostic monitor continually monitors all air bag Supplemental Restraint System (SRS) components and wiring connections for possible faults in the system. If the air bag diagnostic monitor detects a fault in the SRS when the ignition switch is in the RUN position, a Lamp Fault Code (LFC) will be displayed by the air bag indicator, located on the instrument cluster. The air bag diagnostic monitor does not deploy the air bag in the event of a collision. The LH or RH air bag sensor and the safing sensor determine when to deploy the air bag. The air bag diagnostic monitor illuminates the air bag indicator for approximately six seconds when the ignition switch is in the RUN position and then turns the indicator off. This shows that the air bag indicator is operational. If the air bag indicator does not illuminate or the indicator stays on or flashes at any time, a fault has been detected by the air bag diagnostic monitor. LFCs may not be displayed for approximately 30 seconds after the ignition switch is placed in the RUN position. This is the amount of time the air bag diagnostic monitor requires to perform all tests and verify system faults. Each LFC (a series of flashes and pauses of the air bag indicator): ^ represents a two-digit number. ^ is always displayed at least twice. If the air bag diagnostic monitor detects a fault in the SRS, a Diagnostic Trouble Code (DTC) will be written to the air bag diagnostic monitor non-volatile RAM (NVRAM). This DTC will then cause the air bag diagnostic monitor to flash an LFC on the air bag indicator. DTCs can be retrieved with the New Generation Star (NGS) Tester. After repair, the DTC can then be cleared from the NVRAM. If a system fault is present and the air bag indicator is malfunctioning, an audible chime will be heard. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS requires repair. If a fault exists that makes unwanted air bag deployment possible, the air bag diagnostic monitor will attempt to remove deployment power by turning on a solid state switch to blow the 10 A battery Fuse 2. If the 10 A battery fuse has successfully been blown by the air bag diagnostic monitor, the air bag diagnostic monitor will not attempt to blow it again until the proper fault has been repaired and cleared. The air bag diagnostic monitor will store both the unwanted deployment DTC and the loss of deployment power DTC. The loss of deployment power DTC is the highest priority. DTCs are prioritized numerically. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. The air bag diagnostic monitor includes an internal backup power supply. This feature provides sufficient backup power to deploy the air bag in the event the battery or battery cables are damaged in a collision before safing and air bag sensors close. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 8906 Air Bag Control Module: Service and Repair REMOVAL WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: The safing sensor is internal to the air bag diagnostic monitor and is not replaced separately. 1. Disconnect the battery ground cable. 2. Remove the RH cowl side trim panel. 3. Remove the air bag diagnostic monitor 1. Disconnect the two electrical connectors. 2. Remove the screws. 3. Remove the air bag diagnostic monitor. INSTALLATION 1. Follow the removal procedure in reverse order. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect the battery ground cable. WARNING: THE BACKUP POWER SUPPLY ENERGY MUST BE DEPLETED BEFORE ANY AIR BAG COMPONENT REPAIR IS PERFORMED. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the driver side air bag module from the vehicle. WARNING: PLACE THE AIR BAG MODULE ON A BENCH WITH THE TRIM COVER FACING UP TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 4. Connect the air bag simulator to the vehicle harness at the top of the steering column. 5. Remove the passenger side air bag module from the vehicle. WARNING: PLACE THE AIR BAG MODULE ON A BENCH WITH THE DEPLOYMENT DOOR FACING UP TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 6. Connect the air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Reactivation Procedure 1. Disconnect the battery ground cable. WARNING: THE AIR BAG SIMULATORS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. In stall the driver side air bag module. 5. Remove the air bag simulator from the vehicle harness connector at the passenger side air bag module. 6. Install the passenger side air bag module. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 8. Prove out the system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8912 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Are both air bag sensors connected and mounted to the vehicle? [ ] 2. Is the three-way connector at the base of the steering column connected? [ ] 3. Are the air bag modules or air bag simulators connected? [ ] 4. Is the air bag diagnostic monitor connected? [ ] 5. Is the vehicle battery connected? [ ] Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 A tethered seat can be installed in the front seat; put the tether strap over the seatback and attach it to an anchor bracket. An anchor bracket can be installed on the rear edge of the front seat cushion. The provision (attaching hole) is provided in the rear edge of the seat cushion frame. Tether anchor brackets may also be installed to the floor behind the second row seats. The anchor bracket must be installed using the instructions provided with the kit. Contact your Ford dealer for a free child safety belt anchor tether. Carefully follow the instructions provided with the kit. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications Seat Belt: Specifications Safety Belt Anchor Bolt ........................................................................................................................ ........................................ 34-46 N.m (25-33 Lb/Ft) Safety Belt Guide Bolt ......................................................................................................................... ......................................... 34-46 N.m (25-33 Lb/Ft) Safety Belt Guide Nut .......................................................................................................................... ......................................... 34-46 N.m (25-33 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection Seat Belt: Service and Repair Cleaning and Inspection WARNING: DO NOT BLEACH OR RE-DYE THE WEBBING, AS THE WEBBING MAY WEAKEN. 1. Clean the safety belt webbing only with a mild soap solution recommended for cleaning upholstery or carpets. Follow the instructions provided with the soap. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8922 Seat Belt: Service and Repair Removal and Installation Captain's Chair Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Remove the front floor console. 2. Remove the passenger seat safety belt buckle. 1. Use Safety Belt Bolt Bit to remove the bolt. 2. Remove the buckle. 3. On power driver seats, remove the driver seat safety belt buckle. 1. Disconnect the safety belt warning indicator switch electrical connector. 2. Use Safety Belt Bolt Bit to remove the bolt. 3. Remove the buckle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8923 4. On manual driver seats, remove the driver side safety belt buckle. 1. Disconnect the safety belt warning indicator switch electrical connector. 2. Remove the nut. 3. Remove the buckle. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Quad Seat Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8924 Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Position the seat forward. 2. Remove the safety belt buckle. 1. Use Safety Belt Bolt Bit to remove the bolt. 2. Remove the buckle. INSTALLATION 1. To install, reverse the removal procedure. ^ Check for proper operation. 40/60 Split Bench Seat, Center and RH Passenger Safety Belt Bolt Bit Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8925 REMOVAL 1. Remove the safety belt buckle assembly 1. Use Safety Belt Bolt Bit to remove the two bolts. 2. Remove the assembly. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. 40/60 Split Bench Seat, Center and RH Passenger, Front Seat Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8926 T55 "Torx Plus" Bit Special Tool(s) REMOVAL 1. Remove the front passenger safety belt. 1. Use T55 "Torx" Bit to remove the bolt. 2. Feed the belt through the seat cushion pocket and remove the belt. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. 40/60 Split Bench, Driver Seat Safety Belt Bolt Bit Special Tool(s) REMOVAL Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8927 1. Remove the driver seat safety belt buckle. 1. Disconnect the safety belt warning indicator switch electrical connector. 2. Use Safety Belt Bolt Bit to remove the bolt. 3. Remove the buckle. NOTE: To ease removal, position the driver seat in its most rearward position and the passenger seat in its most forward position. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. Front Safety Belt Bolt Bit Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; RH side is similar. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8928 1. Remove the safety belt guide. 1. Lift the bolt cover from the bottom. 2. Remove the nut. 2. Remove the front door scuff plate. 3. Remove the rear door scuff plate. 4. Remove the B-pillar assist handle. 1. Remove the two covers. 2. Remove the two screws. 3. Remove the B-pillar assist handle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8929 5. Position the B-pillar trim panel aside. ^ Remove the front and rear door weather seals. NOTE: Remove the upper attachments first, then the lower attachments. 6. Use Safety Belt Bolt Bit to remove the safety belt anchor bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8930 7. Remove the height adjuster cover. 8. Remove the shoulder safety belt height adjuster. 1. Use Safety Belt Bolt Bit to remove the bolts. 2. Remove the adjuster. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8931 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. NOTE: Bolts should be started by hand. Second Row Seat Safety Belt Bolt Bit Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. 1. Remove the safety belt guide. 1. Lift the nut cover from the bottom. 2. Remove the nut. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8932 2. Remove the C-pillar trim panel. NOTE: Remove upper attachments first, followed by the front lower attachment and the lower rear hook. 3. Remove the height adjuster cover. 4. Remove the shoulder safety belt height adjuster. 1. Use Safety Belt Bolt Bit to remove the bolts. 2. Remove the adjuster. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8933 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. NOTE: Bolts should be started by hand. Front Seat Safety Belt Safety Belt Bolt Bit T55 "Torx Plus" Bit Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. 1. Remove the safety belt guide. 1. Lift the nut cover from the bottom. 2. Remove the nut. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8934 2. Remove the front door scuff plate. 3. Remove the rear door scuff plate. 4. Remove the B-pillar assist handle. 1. Remove the two covers. 2. Remove the two screws. 3. Remove the B-pillar assist handle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8935 5. Position the B-pillar trim panel aside. ^ Remove the front and rear door weather seals. NOTE: Remove the upper attachments first. Then the lower attachments. 6. Use Safety Belt Bolt Bit to remove the safety belt anchor bolt. 7. Remove the front safety belt retractor. 1. Use Safety Belt Bolt Bit to remove the bolt. 2. Remove the retractor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8936 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. NOTE: Before the retractor bolt is installed the retractor bracket should be aligned with the hole in the sheet metal. Second Row Seat Safety Belt Bolt Bit T55 "Torx Plus" Bit Special Tools REMOVAL Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8937 NOTE: This procedure is for the LH side; the RH side is similar. 1. Remove the safety belt guide. 1. Lift the nut cover from the bottom. 2. Remove the nut. 2. Remove the quarter trim panel. 3. Use Safety Belt Bolt Bit to remove the safety belt anchor bolt. 4. Remove the center safety belt retractor. 1. Use Safety Belt Bolt Bit to remove the bolt. 2. Remove the retractor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8938 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. Third Row Seat Safety Belt Bolt Bit Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8939 1. Remove the safety belt guide bolt cover. ^ Carefully pry out at the bottom. 2. Use Safety Belt Bolt Bit to remove the safety belt guide bolt. 3. Remove the quarter trim panel. NOTE: On vehicles equipped with auxiliary A/C, only the auxiliary A/C access panel needs to be removed and not the quarter trim panel. 4. Remove the detachable anchor. ^ Depress the release button. 5. Remove the rear safety belt retractor. 1. Use Safety Belt Bolt Bit to remove the bolt. 2. Remove the retractor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8940 6 Remove the detachable anchor tongue trim cover. 1. Remove the bolt. 2. Remove the pushpin. 3. Remove the trim cover. NOTE: Steps six and seven are only necessary if the detachable anchor tongue has to be replaced. 7. Remove the detachable anchor tongue. 1. Use Safety Belt Bolt Bit to remove the bolt. 2. Remove the detachable anchor tongue. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8941 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8942 Seat Belt: Service and Repair Service Procedures Post Collision Inspection 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. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THAT THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: Safety belt assemblies should be periodically inspected to ensure that they have not become damaged and that they remain in proper operating condition, particularly if they have been subjected to severe stress. Before installing the new safety belt assembly, safety belt retaining areas must be inspected for damage and distortion. If the retaining points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity. 1. Inspect the belts for damage and distortion and replace if necessary. 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. Seat 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 27/64 inch drill bit. 3. Rethread the anchor plate with a 1/2-13 tap (seat belt). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8943 Parts Replacement Chart 4. Install the attachment parts. Original parts are to be replaced with the repair parts indicated in the manufacturer's safety belt Parts Replacement Chart. Unless otherwise specified, use original parts. Seat Belt Without Anchor Plate Thread Damage Replacement of the Weld Nut and/or Reinforcement 1. Expose the suspect anchor point. NOTE: If the B, C or D-pillar safety belt anchor nuts or reinforcements are stripped or missing, they should be replaced with a new nut/reinforcement plate. 2. Drill out two 8 mm (5/16 in) diameter access holes adjacent to the weld nut clearance hole. 3. Thread a length of copper welding wire through the clearance hole and position to secure the weld nut and washer. 4. Use MIG Wire Feed Welder and plug weld a 7/16 inch weld nut and standard washer in place at the two 8 mm (5/16 in) holes. 5. Metal finish as required. 6. Install the restraint system. 7. Perform the functional test. Shoulder Safety Belt Height Adjuster With Stripped Weld Nuts D-Ring Installation Kit Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8944 Special Tool(s) 1. Remove the height adjuster. 2. Use the half-inch drill provided in D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. 3. Apply a suitable lubricant to the M14 x 1.5 tap provided in D-Ring Installation Kit and tap new threads. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. 4. Use a threaded insert (part number N807170-5190) provided in D-Ring Installation Kit and screw it into the retapped hole until it is slightly below the surface. 5. Use a hammer to lightly tap the installation tool provided in D-Ring Installation Kit several times to seat the insert keys. NOTE: If the two bolts on the height adjuster are not stripped. If the bolts are stripped, replace the height adjuster. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Specifications Seat Belt Buckle: Specifications Driver Seat Safety Belt Buckle Bolt .............................................................................................................................................. 34-46 N.m (25-33 Lb/Ft) Driver Seat Safety Belt Buckle Nut .............................................................................................................................................. 34-46 N.m (25-33 Lb/Ft) Passenger Seat Safety Belt Buckle Bolt ........................................................................................................................................ 34-46 N.m (25-33 Lb/Ft) Quad Seat Safety Belt Buckle Bolt ............................................................................................................................................... 34-46 N.m (25-33 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Locations > Front Seats Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Locations > Front Seats > Page 8950 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Locations > Front Seats > Page 8951 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair Seat Belt Buckle: Service and Repair Captain's Chair Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Remove the front floor console. 2. Remove the passenger seat safety belt buckle. 1. Use Safety Belt Bolt Bit to remove the bolt. 2. Remove the buckle. 3. On power driver seats, remove the driver seat safety belt buckle. 1. Disconnect the safety belt warning indicator switch electrical connector. 2. Use Safety Belt Bolt Bit to remove the bolt. 3. Remove the buckle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8954 4. On manual driver seats, remove the driver side safety belt buckle. 1. Disconnect the safety belt warning indicator switch electrical connector. 2. Remove the nut. 3. Remove the buckle. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8955 Seat Belt Buckle: Service and Repair Quad Seat Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Position the seat forward. 2. Remove the safety belt buckle. 1. Use Safety Belt Bolt Bit to remove the bolt. 2. Remove the buckle. INSTALLATION 1. To install, reverse the removal procedure. ^ Check for proper operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8956 Seat Belt Buckle: Service and Repair 40/60 Split Bench Seat, Center and RH Passenger, Front Seat T55 "Torx Plus" Bit Special Tool(s) REMOVAL 1. Remove the front passenger safety belt. 1. Use T55 "Torx" Bit to remove the bolt. 2. Feed the belt through the seat cushion pocket and remove the belt. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8957 Seat Belt Buckle: Service and Repair 40/60 Split Bench Seat, Center and RH Passenger Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Remove the safety belt buckle assembly 1. Use Safety Belt Bolt Bit to remove the two bolts. 2. Remove the assembly. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8958 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8959 Seat Belt Buckle: Service and Repair 40/60 Split Bench, Driver Seat Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Remove the driver seat safety belt buckle. 1. Disconnect the safety belt warning indicator switch electrical connector. 2. Use Safety Belt Bolt Bit to remove the bolt. 3. Remove the buckle. NOTE: To ease removal, position the driver seat in its most rearward position and the passenger seat in its most forward position. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Description and Operation Seat Belt Extension: Description and Operation In certain cases, the safety belt may be too short even when it is fully extended. About 20 cm (8 in) can be added to the belt length by using a safety belt extension. Safety belt extensions are available through the dealership parts department. Safety belt extensions are only available with black webbing. As well, the standard buckle must be from the same manufacturer as the belt system to which it is attached. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Specifications Seat Belt Height Adjuster: Specifications Safety Belt Height Adjuster .......................................................................................................................................................... 34-46 N.m (25-33 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Locations > Front Seats Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Locations > Front Seats > Page 8968 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt Seat Belt Height Adjuster: Service and Repair Front Safety Belt Safety Belt Bolt Bit Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; RH side is similar. 1. Remove the safety belt guide. 1. Lift the bolt cover from the bottom. 2. Remove the nut. 2. Remove the front door scuff plate. 3. Remove the rear door scuff plate. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt > Page 8971 4. Remove the B-pillar assist handle. 1. Remove the two covers. 2. Remove the two screws. 3. Remove the B-pillar assist handle. 5. Position the B-pillar trim panel aside. ^ Remove the front and rear door weather seals. NOTE: Remove the upper attachments first, then the lower attachments. 6. Use Safety Belt Bolt Bit to remove the safety belt anchor bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt > Page 8972 7. Remove the height adjuster cover. 8. Remove the shoulder safety belt height adjuster. 1. Use Safety Belt Bolt Bit to remove the bolts. 2. Remove the adjuster. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt > Page 8973 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. NOTE: Bolts should be started by hand. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt > Page 8974 Seat Belt Height Adjuster: Service and Repair Removal and Installation Safety Belt Bolt Bit Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. 1. Remove the safety belt guide. 1. Lift the nut cover from the bottom. 2. Remove the nut. 2. Remove the C-pillar trim panel. NOTE: Remove upper attachments first, followed by the front lower attachment and the lower rear hook. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt > Page 8975 3. Remove the height adjuster cover. 4. Remove the shoulder safety belt height adjuster. 1. Use Safety Belt Bolt Bit to remove the bolts. 2. Remove the adjuster. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. NOTE: Bolts should be started by hand. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt > Page 8976 Seat Belt Height Adjuster: Service and Repair Shoulder Safety Belt Height Adjuster With Stripped Weld Nuts D-Ring Installation Kit Special Tool(s) 1. Remove the height adjuster. 2. Use the half-inch drill provided in D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. 3. Apply a suitable lubricant to the M14 x 1.5 tap provided in D-Ring Installation Kit and tap new threads. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. 4. Use a threaded insert (part number N807170-5190) provided in D-Ring Installation Kit and screw it into the retapped hole until it is slightly below the surface. 5. Use a hammer to lightly tap the installation tool provided in D-Ring Installation Kit several times to seat the insert keys. NOTE: If the two bolts on the height adjuster are not stripped. If the bolts are stripped, replace the height adjuster. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Testing and Inspection Seat Belt Reminder Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Specifications Seat Belt Retractor: Specifications Safety Belt Retractor Bolt ............................................................................................................................................................. 34-46 N.m (25-33 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Locations > Front Seats Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Locations > Front Seats > Page 8985 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Locations > Page 8986 Seat Belt Retractor: Description and Operation NOTE: When replacing an Automatic Locking Retraction (ALR) equipped retractor, the retractor should be checked to make sure it is not in the ALR mode after installation. All outboard continuous-loop, three-point retractor systems, except the driver position, are equipped with the ALR system. This system is used when installing a child safety seat in an outboard seating position or when a tight lap/shoulder belt is desired by the occupant. The ALR system is automatically engaged when the webbing is fully extracted from the retractor. As the webbing is retracted back onto the spool, an audible clicking sound is made indicating the retractor is in the ALR mode. The ALR mode is automatically disengaged when most of the webbing is retracted back onto the spool. The ALR mode is disengaged when the audible clicking sound ceases and the webbing is free to move in or out of the retractor indicating a normal mode of operation. The automatic locking mode must be used when installing a child safety seat in the front passenger and rear outboard passenger seating positions where dual locking mode retractors are provided. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front - Driver Side Seat Belt Retractor: Service and Repair Front - Driver Side Safety Belt Bolt Bit T55 "Torx Plus" Bit Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. 1. Remove the safety belt guide. 1. Lift the nut cover from the bottom. 2. Remove the nut. 2. Remove the front door scuff plate. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front - Driver Side > Page 8989 3. Remove the rear door scuff plate. 4. Remove the B-pillar assist handle. 1. Remove the two covers. 2. Remove the two screws. 3. Remove the B-pillar assist handle. 5. Position the B-pillar trim panel aside. ^ Remove the front and rear door weather seals. NOTE: Remove the upper attachments first. Then the lower attachments. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front - Driver Side > Page 8990 6. Use Safety Belt Bolt Bit to remove the safety belt anchor bolt. 7. Remove the front safety belt retractor. 1. Use Safety Belt Bolt Bit to remove the bolt. 2. Remove the retractor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front - Driver Side > Page 8991 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. NOTE: Before the retractor bolt is installed the retractor bracket should be aligned with the hole in the sheet metal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front - Driver Side > Page 8992 Seat Belt Retractor: Service and Repair Second Row Seat - Driver Side Safety Belt Bolt Bit T55 "Torx Plus" Bit Special Tools REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. 1. Remove the safety belt guide. 1. Lift the nut cover from the bottom. 2. Remove the nut. 2. Remove the quarter trim panel. 3. Use Safety Belt Bolt Bit to remove the safety belt anchor bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front - Driver Side > Page 8993 4. Remove the center safety belt retractor. 1. Use Safety Belt Bolt Bit to remove the bolt. 2. Remove the retractor. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front - Driver Side > Page 8994 Seat Belt Retractor: Service and Repair Third Row Seat Safety Belt Safety Belt Bolt Bit Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. 1. Remove the safety belt guide bolt cover. ^ Carefully pry out at the bottom. 2. Use Safety Belt Bolt Bit to remove the safety belt guide bolt. 3. Remove the quarter trim panel. NOTE: On vehicles equipped with auxiliary A/C, only the auxiliary A/C access panel needs to be removed and not the quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front - Driver Side > Page 8995 4. Remove the detachable anchor. ^ Depress the release button. 5. Remove the rear safety belt retractor. 1. Use Safety Belt Bolt Bit to remove the bolt. 2. Remove the retractor. 6 Remove the detachable anchor tongue trim cover. 1. Remove the bolt. 2. Remove the pushpin. 3. Remove the trim cover. NOTE: Steps six and seven are only necessary if the detachable anchor tongue has to be replaced. 7. Remove the detachable anchor tongue. 1. Use Safety Belt Bolt Bit to remove the bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front - Driver Side > Page 8996 2. Remove the detachable anchor tongue. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information > Description and Operation Seat Belt Warning Timer: Description and Operation 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Air Bag Sensor Screws .......................................................................................................................................................... 10.2-13.8 N.m (90-122 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Primary Crash Sensor Impact Sensor: Locations Left Front Primary Crash Sensor Engine View The Left Primary Crash Sensor is located at the left front of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Primary Crash Sensor > Page 9006 Impact Sensor: Locations Right Primary Crash Sensor Engine View The Right Primary Crash Sensor is located at the right front of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 9007 Impact Sensor: Description and Operation WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION WHERE THE RADIATOR GRILLE OPENING PANEL, FRAME RAILS, OR COWL PANELS HAVE BEEN DAMAGED, INSPECT THE SENSOR MOUNTING BRACKETS FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAGS ARE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE SENSOR MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. NOTE: Undamaged air bag sensors will reset automatically after a collision and can be reused. The air bag Supplemental Restraint System (SRS) contains the following three sensors. ^ LH air bag sensor and bracket. ^ RH air bag sensor and bracket. ^ Safing sensor that is internal to the air bag diagnostic monitor. At least two sensors (one air bag sensor and the safing sensor) must be closed to inflate the air bag. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 9008 Impact Sensor: Service and Repair 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. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. NOTE: A repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable. 2. Remove the radiator air deflector. 1. Remove the push clips. 2. Remove the radiator air deflector 3. Disconnect the air bag sensor electrical connector (RH shown, LH similar). 4. Remove the air bag sensor. 1. Remove the screws. 2. Remove the air bag sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 9009 INSTALLATION WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED. NOTE: A repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Follow the removal procedure in reverse order. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Description and Operation Safing Sensor: Description and Operation WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION WHERE THE RADIATOR GRILLE OPENING PANEL, FRAME RAILS, OR COWL PANELS HAVE BEEN DAMAGED, INSPECT THE SENSOR MOUNTING BRACKETS FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAGS ARE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE SENSOR MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. NOTE: Undamaged air bag sensors will reset automatically after a collision and can be reused. The air bag Supplemental Restraint System (SRS) contains the following three sensors. ^ LH air bag sensor and bracket. ^ RH air bag sensor and bracket. ^ Safing sensor that is internal to the air bag diagnostic monitor. At least two sensors (one air bag sensor and the safing sensor) must be closed to inflate the air bag. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9018 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Accessory Delay Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications Antenna: Specifications Wheel Opening Moulding Screws ................................................................................................................................................. 1.6-2.0 N.m (14-17 Lb/In) Inner Fender Splash Shield Screws ................................................................................................................................................ 10-14 N.m (7.5-10 Lb/Ft) Radio Antenna Base Screws .......................................................................................................................................................... 1.6-2.2 N.m (14-19 Lb/In) Antenna ...................................................................................................... ................................................................................... 3.4-3.6 N.m (30-31 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 9022 Antenna: Description and Operation The antenna and related components consist of: ^ Radio antenna lead in cable. ^ Fender mounted antenna base and antenna. The antenna receives AM and FM waves. The radio waves are sent to the radio chassis through the radio antenna lead in cable. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 9023 Antenna: Service and Repair REMOVAL 1. If equipped, remove the front wheel opening moulding. 1 Remove the pushpin. 2 Remove the screws. 3 Carefully pry the wheel opening moulding to release the nine clips. 2. Remove the inner fender splash shield. 1 Remove the screws. 2 Pull the inner fender splash shield to release the clips. 3. Disconnect the radio antenna lead in cable from the antenna base. 4. Remove the radio chassis. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 9024 5. Push the radio antenna lead in cable into the passenger compartment. 1 Disconnect the radio antenna lead in cable from the clip. 2 Push the grommet into the passenger compartment. 3 Push the radio antenna lead in cable into the passenger compartment. 6. Remove the radio antenna lead in cable. 1 Disconnect the cable clips from the lower metal instrument panel channel. 2 Disconnect the cable clip between the instrument panel channel and the radio end of cable. 3 Remove the radio antenna lead in cable from under the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 9025 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module Alarm Module: Locations Anti-Theft Transceiver Module Instrument Panel View The Anti Theft-Transceiver Module is located behind the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 9031 Alarm Module: Locations Passive Anti-Theft System Module Body View The Passive Anti-Theft System Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 9032 Alarm Module: Locations Remote Anti-Theft Personality Module Body Views Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 9033 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module Passive Anti-theft System Control Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 9036 Anti-theft Transceiver Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 9037 Alarm Module: Diagrams Remote Anti-Theft Personality Module Remote Anti-Theft Personality Module (C257) Remote Anti-Theft Personality Module (C256) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Key Programming - New Key With Diagnostic Tool Alarm Module: Service and Repair Key Programming - New Key With Diagnostic Tool NOTE: Before starting this procedure, make sure the key(s) you want to program have the correct mechanical cut. 1. Plug in NGS tester (requires V10 card or higher). ^ (Or use V8.0 or higher and select DN101 4V as vehicle). 2. Turn the key to RUN. 3. If the key is already programmed, the THEFT indicator proves out after two seconds or if the key is not programmed, the THEFT indicator flashes rapidly. 4. Enter PATS Function Test and select ERASE IGNITION KEY. 5. TEST in PROGRESS will display on the screen. If a programmed key is being used, all keys will be erased within five seconds. If a non programmed key is being used, erasing will take a minimum of eight minutes. 6. TEST COMPLETE will display on screen. All keys are now erased. 7. Turn the key to OFF, and then back to RUN. 8. THEFT indicator proves out after two seconds. 9. PATS key is now programmed. 10. Additional keys may be programmed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Key Programming - New Key With Diagnostic Tool > Page 9040 Alarm Module: Service and Repair Key Programming - New Key Without Diagnostic Tool NOTE: Before starting this procedure, make sure the key(s) you want to program have the correct mechanical cut. 1. Insert the non programmed key in the ignition and turn to RUN. 2. THEFT indicator flashes rapidly. 3. After 15 minutes of flashing, the THEFT indicator will stop flashing. 4. Within five minutes after the THEFT indicator has stopped flashing, turn the ignition key to OFF and back to RUN. 5. After 15 minutes of flashing, the THEFT indicator will stop flashing. 6. Within five minutes after the THEFT indicator has stopped flashing, turn the ignition key to OFF and back to RUN. 7. After 15 minutes of flashing, the THEFT indicator will stop flashing. 8. All originally programmed keys are now erased, and only the key in the ignition is programmed. 9. Additional keys may be programmed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Key Programming - New Key With Diagnostic Tool > Page 9041 Alarm Module: Service and Repair Key Programming - Spare Key NOTE: ^ Before starting this procedure, make sure the key(s) you want to program have the correct mechanical cut. ^ Performing this procedure does not erase existing programmed keys. 1. Insert the programmed key in the ignition. Turn to RUN. 2. THEFT indicator proves out after two seconds. 3. Remove the programmed key. 4. Within 15 seconds, insert the new key in the ignition and turn to RUN. 5. THEFT indicator proves out after two seconds. 6. The extra key is now programmed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Key Programming - New Key With Diagnostic Tool > Page 9042 Alarm Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the PATS module. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the PATS module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Key Programming - New Key With Diagnostic Tool > Page 9043 The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. ^ All vehicle keys must now be programmed. The first key will automatically program, and the additional keys should follow spare key programming. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Specifications Alarm System Transponder: Specifications Anti-Theft Switch - Transceiver Assembly Screw ........................................................................................................................ 1.8-2.6 N.m (16-23 Lb/In) Battery Ground Cable ................................................................................................................ ........................................................ 7-10 N.m (62-89 Lb/In) Passive Anti-Theft System Module Screws ................................................................................................................................ 4.5-6.3 N.m (41-56.2 Lb/In) Steering Column Shroud Screws ................................................................................................................................................... 3-5 N.m (31.2-33.2 Lb/In) Tilt Wheel Handle and Shank ..................................................................................................................................................... 0.7-1.1 N.m (6.2-6.5 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service and Repair > New Key Programming - With Diagnostic Tool Alarm System Transponder: Service and Repair New Key Programming - With Diagnostic Tool NOTE: Before starting this procedure, make sure the key(s) you want to program have the correct mechanical cut. 1. Plug in NGS tester (requires V10 card or higher). ^ (Or use V8.0 or higher and select DN101 4V as vehicle). 2. Turn the key to RUN. 3. If the key is already programmed, the THEFT indicator proves out after two seconds or if the key is not programmed, the THEFT indicator flashes rapidly. 4. Enter PATS Function Test and select ERASE IGNITION KEY. 5. TEST in PROGRESS will display on the screen. If a programmed key is being used, all keys will be erased within five seconds. If a non programmed key is being used, erasing will take a minimum of eight minutes. 6. TEST COMPLETE will display on screen. All keys are now erased. 7. Turn the key to OFF, and then back to RUN. 8. THEFT indicator proves out after two seconds. 9. PATS key is now programmed. 10. Additional keys may be programmed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service and Repair > New Key Programming - With Diagnostic Tool > Page 9049 Alarm System Transponder: Service and Repair New Key Programming - Without Diagnostic Tool NOTE: Before starting this procedure, make sure the key(s) you want to program have the correct mechanical cut. 1. Insert the non programmed key in the ignition and turn to RUN. 2. THEFT indicator flashes rapidly. 3. After 15 minutes of flashing, the THEFT indicator will stop flashing. 4. Within five minutes after the THEFT indicator has stopped flashing, turn the ignition key to OFF and back to RUN. 5. After 15 minutes of flashing, the THEFT indicator will stop flashing. 6. Within five minutes after the THEFT indicator has stopped flashing, turn the ignition key to OFF and back to RUN. 7. After 15 minutes of flashing, the THEFT indicator will stop flashing. 8. All originally programmed keys are now erased, and only the key in the ignition is programmed. 9. Additional keys may be programmed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service and Repair > New Key Programming - With Diagnostic Tool > Page 9050 Alarm System Transponder: Service and Repair Key Programming - Spare Key NOTE: ^ Before starting this procedure, make sure the key(s) you want to program have the correct mechanical cut. ^ Performing this procedure does not erase existing programmed keys. 1. Insert the programmed key in the ignition. Turn to RUN. 2. THEFT indicator proves out after two seconds. 3. Remove the programmed key. 4. Within 15 seconds, insert the new key in the ignition and turn to RUN. 5. THEFT indicator proves out after two seconds. 6. The extra key is now programmed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service and Repair > New Key Programming - With Diagnostic Tool > Page 9051 Alarm System Transponder: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Twist the tilt wheel handle and shank and remove. NOTE: The steering wheel is removed for clarity. 3. Remove the lower steering column shroud. 1 Remove the three screws. 2 Remove the lower steering column shroud. NOTE: The steering wheel is removed for clarity. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service and Repair > New Key Programming - With Diagnostic Tool > Page 9052 4. 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 (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 5. Carefully pry to release the four clips and remove the steering column opening cover. 6. Remove the upper steering column shroud. NOTE: The steering wheel is removed for clarity. 7. Remove the transceiver assembly. 1 Remove the screw. 2 Locate the rib on the steering column lock cylinder housing, and gently pry the anti-theft transceiver over the rib. NOTE: Only apply pressure or leverage below the key cylinder lower rib. 3 Disconnect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service and Repair > New Key Programming - With Diagnostic Tool > Page 9053 INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. ^ The steering wheel is removed for clarity. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Ignition Key In Signal, Antitheft > Component Information > Service and Repair Ignition Key In Signal: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the (A) ignition switch lock cylinder release tab while pulling out the (B) ignition switch lock cylinder. 3. Remove the key in ignition warning switch. 1 Pry the clip downward. 2 Release the key-in-ignition warning switch from the rear of the ignition switch lock cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Ignition Key In Signal, Antitheft > Component Information > Service and Repair > Page 9057 INSTALLATION 1. To install, reverse the removal procedure. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 (V8-281 4.6L SOHC (1998)) 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 9063 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 (V8-281 4.6L SOHC (1998)) 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 9064 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications RAP Module Nuts ................................................................................................................................ ......................................................... 7 Nm (62 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 9068 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 9069 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 9070 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Disconnect the C257 and C256 Remote Anti-theft Personality (RAP) module electrical connectors. 3. Remove the nuts and the RAP module. NOTE: On Expedition and later build Navigators, the antenna is internal to the module and must be replaced as an assembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 9071 strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Description and Operation Keyless Entry Transmitter: Description and Operation NOTE: The remote entry features will not function when the ignition switch is in the RUN or ACC position. The keyless entry remote transmitter initiates the following electronic door lock and memory (Navigator only) system functions: ^ Unlocks the driver door. ^ Unlocks the driver door and moves the memory seat and mirrors into their corresponding memory positions. (Only available with the remote memory feature). ^ Unlocks all doors. ^ Locks all doors. ^ Enables the panic alarm. ^ Turns on the interior lamps when unlocking and off when locking. ^ Chirps the horn once when the LOCK button on the keyless entry remote transmitter is pressed twice and all doors are closed. ^ Chirps the horn twice when the LOCK button on the keyless entry remote transmitter is pressed twice and a door is left open. ^ Allows up to four keyless entry remote transmitters to be programmed. NOTE: If more than five seconds have elapsed since the first press of the UNLOCK button, pressing the UNLOCK button again will only unlock the driver door a second time. To unlock the driver door press the UNLOCK button on the keyless entry remote transmitter. To unlock all doors press the UNLOCK button on the keyless entry remote transmitter a second time, within five seconds of the first unlock. To lock all doors press the LOCK button on the keyless entry remote transmitter once. To confirm that the doors have been locked press the LOCK button again, within five seconds of the first press. The horn will chirp once if the doors Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Description and Operation > Page 9075 have locked and all doors are closed. The horn will chirp twice if a door is still open. To activate the panic alarm press the red PANIC button on the keyless entry remote transmitter. The horn will sound and the headlamps and exterior lamps will flash for a maximum of two minutes and 45 seconds. To deactivate the panic alarm press the red PANIC button again on the keyless entry remote transmitter or turn the ignition switch to RUN/ACC. Enable/Disable Mode The enable/disable mode allows the autolock and memory seat/mirror (Navigator only) features to be turned off and on. There are PIDS in RAP (Autolock and MEM-SEAT) which reflect if the feature is ON or OFF. The RAP Active Command Module Configuration can be used to turn "Autolock" on/off and turn "Move MEM-SEAT w/Key fob" on/off or the enable/disable mode is entered when the following series of steps is performed: 1. Close all of the doors. 2. Confirm that the ignition switch is in the OFF position. NOTE: Steps 3 through 7 must be performed within 30 seconds. 3. Turn the ignition switch from OFF to RUN. 4. Press the power door lock UNLOCK button three times. 5. Turn the ignition switch from RUN to OFF. 6. Press the power door lock UNLOCK button three times. 7. Turn the ignition switch from OFF to RUN. 8. Verify that the RAP module chirps the horn. This indicates that the RAP module is now in the enable/disable mode and ready to accept program changes. 9. To change Autolock press the power door lock UNLOCK button one time to command the RAP module to toggle the autolock feature ON or OFF. 10. To change if the memory seat/mirrors will move when the keyfob unlock button is pressed, press the power door lock unlock button two times. 11. Press the power door lock LOCK button once to enter the command. 12. Verify that the vehicle horn chirps one time (Autolock feature) or two short chirps (memory seat recall feature) to signal the RAP module confirmation of the command. There should only be one chirp (Autolock feature) or two short chirps (memory seat recall feature) indicating that the feature has been disabled. If one chirp (for Autolock) or two chirps (for Memory Seat) is heard, followed by a longer honk, the feature has just been enabled. Return to step 9. 13. Turn the ignition switch to the OFF position to exit the enable/disable mode. 14. Verify that the RAP module chirps the horn once to indicate that a feature has been changed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Description and Operation > Page 9076 Keyless Entry Transmitter: Service and Repair TRANSMITTER PROGRAMMING NOTE: ^ The keyless entry remote transmitters are reprogrammable and must be set at the same time. ^ To program (or reprogram) the keyless entry remote transmitters into the RAP module, perform the following steps: 1. Turn the ignition switch from OFF to RUN eight times within ten seconds, ending in RUN. If the RAP module has successfully entered the program mode, it will lock and then unlock all doors. 2. Press any button on the keyless entry remote transmitter, and the doors will lock and then unlock to confirm that each keyless entry remote transmitter has been programmed. 3. If the door locks do not respond for any keyless entry remote transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Diagnosis and Testing. 4. Turn the ignition switch to the OFF position, or wait up to five minutesafter step 2, to exit the program mode. If a keyless entry remote transmitter has been programmed (or reprogrammed), the RAP module will lock and unlock all doors one last time to confirm. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Testing and Inspection Security Lamp/Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation Driver/Vehicle Information Display: Description and Operation NOTE: ^ The Distance To Empty (DTE) display may be inaccurate if the vehicle is started while parked on an incline. ^ Fuel fills of less than 22.7 liters (six gallons) may not be detected by the message center. The message center displays: ^ Compass direction. ^ DTE. ^ Average (AVG) fuel economy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 9083 ^ Instantaneous (INST) fuel economy. The message center inputs are: ^ Compass sensor module data (+) and (-). ^ VSS. ^ Fuel level sensor data. ^ Data Output Line (DOL) fuel flow data from the PCM. Average Fuel Economy-Resetting NOTE: Only the AVG fuel economy can be reset. DTE and INST displays cannot be reset. The average fuel economy display is resettable. To reset, the ignition switch must be in the RUN position (with or without the engine running) and the message center must be in the AVG fuel economy mode. Press and release the MODE and E/M buttons simultaneously. If the vehicle is parked while resetting, the AVG fuel economy will display 0.0 (English mode) or 99.9 (metric mode). If the vehicle is in motion, the AVG fuel economy will display the current INST fuel economy (English mode or metric mode). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the Visual Inspection Chart. VISUAL INSPECTION CHART Mechanical ^ Damaged overhead trip computer ^ Damaged Vehicle Speed Sensor (VSS) ^ Damaged compass sensor module or loose mounting ^ Damaged Powertrain Control Module (PCM) Electrical ^ Blown fuse: Fuse 2 (5A) - Fuse 6 (5A) ^ Damaged wiring harness ^ Loose or corroded connections 3. If the fault is not visually evident, perform the Message Center Self-Test. See: Component Tests and General Diagnostics/Message Center Self-Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9086 Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures NOTE: Always check ZONE and Calibration (CAL) adjustments before replacing the compass sensor module. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9087 Driver/Vehicle Information Display: Pinpoint Tests Test Note Do not proceed to the Pinpoint Tests until the Message Center Self-Test has been performed. A: The Compass Is Inaccurate A1 - A2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9088 A3 - A4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9089 A5 - A6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9090 A7 B: The Message Center Display Is Blank Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9091 B1 - B2 B3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9092 B4 - B5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9093 B6 C1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9094 D: Dist. To Empty/Av/Instant Fuel Economy Inop/Incorrect D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9095 D2 - D3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9096 D4 - D5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9097 Driver/Vehicle Information Display: Component Tests and General Diagnostics Compass Zone Adjustment 1. The zone setting is factory pre-set to Zone 8. Check the Compass Calibration Zone map to verify the correct compass zone setting for your geographic location. 2. Insert an appropriate-diameter rod, preferably non-metallic, into the switch access hole underneath the compass module. Gently press the switch for one to two seconds until ZONE and the current zone setting are displayed. 3. Release the switch. 4. Press the switch repeatedly to cycle the display through all possible zone settings. Stop cycling when the correct zone setting for your location is displayed. 5. Release the switch to exit the zone setting mode. Message Center Self-Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9098 Message Center 1. The Message Center Self-Test can be entered by pressing the E/M and MODE buttons simultaneously while starting the vehicle. After entering the Message Center Self-Test release the E/M and MODE buttons. Advancing to a desired test is accomplished by pressing the MODE button. To abort the Message Center Self-Test, turn the ignition switch to the OFF position. NOTE: Vehicle doors must be closed and the engine must be running while in the Message Center Self-Test mode to receive accurate data. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9099 Part 1 Of 3 Part 2 Of 3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9100 Part 3 Of 3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Calibration Adjustment Driver/Vehicle Information Display: Service and Repair Calibration Adjustment 1. For optimum calibration, turn off all non-essential electrical accessories (rear window defrost, heater/air conditioning, map lamps, wipers, etc.) and make sure all doors are shut. 2. Drive to an open, level area away from large metallic objects or structures and high voltage lines. 3. Insert an appropriate-diameter rod, preferably non-metallic, into the switch access hole underneath the compass module. Press gently for two to four seconds until CAL and a direction are displayed. 4. Release the switch and drive slowly in a circle until CAL disappears from the display (about two to three circles). 5. The compass is now calibrated. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Calibration Adjustment > Page 9103 Driver/Vehicle Information Display: Service and Repair Compass Zone Adjustment 1. The zone setting is factory pre-set to Zone 8. Check the Compass Calibration Zone map to verify the correct compass zone setting for your geographic location. 2. Insert an appropriate-diameter rod, preferably non-metallic, into the switch access hole underneath the compass module. Gently press the switch for one to two seconds until ZONE and the current zone setting are displayed. 3. Release the switch. 4. Press the switch repeatedly to cycle the display through all possible zone settings. Stop cycling when the correct zone setting for your location is displayed. 5. Release the switch to exit the zone setting mode. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Calibration Adjustment > Page 9104 Driver/Vehicle Information Display: Service and Repair Message Center Assembly REMOVAL 1. Open the overhead sunglasses compartment and remove the screw. 2. Grasp the front of the overhead console and pull down to remove the console. 3. Disconnect the electrical connectors. 4. Remove the message center. 1 Depress the lock tab underneath the in-line electrical connector. 2 Remove the in-line connector. 3 Remove the screws. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Calibration Adjustment > Page 9105 4 Remove the message center. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Calibration Adjustment > Page 9106 Driver/Vehicle Information Display: Service and Repair Vehicle Demagnetizing CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a cloth over the vehicle's roof to protect the vehicle's surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. NOTE: ^ The demagnetizing process requires the use of a demagnetizing coil commonly used by television service technicians to demagnetize television tubes. ^ To demagnetize, use a constant circular motion over the vehicle's roof. Do not turn off the demagnetizer while sweeping the vehicle's roof to prevent remagnetizing ferrous materials contained in the vehicle. ^ During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite the handle) is closest to the vehicle's surface. 1. Demagnetize the front third of the vehicle's roof. 1 Turn on the demagnetizer at least 1 meter (3 ft) away from the vehicle. 2 Holding the demagnetizer no more than 2.5 cm (1 in) from the roof and starting on the passenger side, demagnetize the front third of the roof closest to the windshield using a constant circular motion. Keep the circle's radius within 30 cm (12 in) while sweeping across the entire surface of the roof closest to the windshield. Continue the circular motion four times. 3 After the fourth pass and without stopping, move the demagnetizer at least 1 meter (3 ft) away from the vehicle. 4 Turn the demagnetizer off. 2. 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. NOTE: The demagnetizer must be located over the outside of the windshield no greater than 2.5 cm (1 in). 3. Perform the Compass Zone Adjustment procedure. 4. Perform the Calibration Adjustment procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 9107 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Specifications Multifunction Electronic Control Module: Specifications GEM Screws ........................................................................................................................................ ........................................... 0.9-1.3 N.m (8-12 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Specifications > Page 9111 Multifunction Electronic Control Module: Locations Instrument Panel View The Generic Electronic Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9114 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9115 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9116 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9117 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9118 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9119 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9120 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9121 Multifunction Electronic Control Module: Connector Views Generic Electronic Module (C239) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9122 Generic Electronic Module (C267) Generic Electronic Module (C240) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9123 Generic Electronic Module (C241) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9124 Multifunction Electronic Control Module: Electrical Diagrams Generic Electronic Module (Part 1 Of 5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9125 Generic Electronic module (Part 2 of 5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9126 Generic Electronic module (Part 3 of 5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9127 Generic Electronic module (Part 4 of 5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9128 Generic Electronic module (Part 5 of 5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 9129 Multifunction Electronic Control Module: Description and Operation The Generic Electronic Module (GEM) constantly monitors its subsystems for concerns. If a concern is found in one of the subsystems, the GEM will record the concern in the form of a Diagnostic Trouble Code (DTC). The ignition switch position is very important to the GEM function. Often times, erratic or unexpected GEM function can be traced to problems with these GEM inputs. The GEM controls the following features: ^ Wipers/washers (front/rear). ^ Warning chimes. ^ Battery saver. ^ Illuminated entry and courtesy lamps. ^ Driver power window. ^ Accessory delay. ^ 4-wheel drive. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 9130 There are four modes of operation for the front wipers: speed dependent interval, slow, fast and wash. These modes are only active with the ignition switch in the RUN or ACC position. The two modes of operation for the rear wipers are interval and wash. These modes are only active with the ignition switch in the RUN or ACC positions and with both the liftgate and liftgate glass closed. The GEM controls five warning chimes and lamps: headlamps operating without the ignition on (chime only), door ajar (chime and lamp), key-in-ignition (chime only), driver seat safety belt warning (chime and lamp), and low washer fluid warning (chime and lamp). The battery saver feature removes extended interior lamp power drains from the battery. The GEM will keep power available for all interior lights and under hood lamp circuits for 40 minutes after the ignition switch is turned off. The GEM illuminates the interior courtesy lamps when any door is ajar. The GEM also provides illuminated entry when the unlock button is used to unlock the vehicle. The GEM illuminates the running board lamps when the interior lamps are activated (see courtesy lamps and illuminated entry description above) and the ignition switch is not in the RUN position. The delayed accessory feature provides power to the power windows for ten minutes after the ignition switch is moved from the RUN to the OFF position. If during this ten-minute period either front door is opened, the delayed accessory relay will be de-energized. This system is equipped with Automatic 4-Wheel Drive (A4WD). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Driver Seat Module Multifunction Electronic Control Module: Service and Repair Driver Seat Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the driver seat. 3. Disconnect the driver seat module electrical connectors. 4. Remove the screws from the driver seat module and release the module retainers from the module bracket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Driver Seat Module > Page 9133 Multifunction Electronic Control Module: Service and Repair Generic Electronic Module (GEM) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the steering column opening cover. 3. Remove the (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel. 4. Remove the (A) instrument panel fuse junction panel bolts and remove the (B) interior fuse junction panel nuts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Driver Seat Module > Page 9134 5. Disconnect the (A) GEM electrical connectors from the (B) GEM. 6. Remove the screws and the GEM. INSTALLATION NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 1. To install, reverse the removal procedure. ^ Check for proper operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation > Memory Power Driver Seat Operation Seat Memory Switch: Description and Operation Memory Power Driver Seat Operation The memory driver seat feature allows the driver to program a personalized seat position that can be recalled using the memory switches or remote entry key fob. There are three memory settings possible. The outside rear view mirror positions are also stored and recalled with the power driver seat positions. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 9140 Seat Memory Switch: Description and Operation Programming Seat Positions A power driver seat position can be stored at any time. The driver must move the seat to the desired position using the driver seat switch assembly. The driver must then depress the memory SET switch which activates the memory SET switch Light Emitting Diode (LED). Within five seconds (before the LED goes out), the driver must select a memory position. Memory 1 is selected by depressing memory switch 1. Memory 2 is selected by depressing memory switch 2. Memory 3 is selected by depressing both memory switch 1 and memory switch 2 simultaneously. If no memory switch input is received within the five second time limit, the operation is aborted and the memory SET switch LED is turned off. If one of the following inputs is received during the five secondprogramming limit, the operation is aborted and the memory SET switch LED is turned off: - Power driver seat switch. - Power outside rear view mirror switch. - Memory SET switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 9141 Seat Memory Switch: Description and Operation Recalling A Stored Seat Position NOTE: A memory recall can be initiated only if the vehicle is in PARK or NEUTRAL gear and the ignition switch is not in START. A memory recall in progress will not be affected by moving the ignition switch to START or by moving the gearshift lever out of PARK or NEUTRAL. Once the driver has stored the desired driver seat position, the driver can recall the setting by depressing the corresponding memory switch or by using a programmed remote entry transmitter. ^ The driver can recall the desired driver seat position by depressing one or both of the memory recall switches. Depressing memory switch 1 will initiate a recall of the power driver seat position stored in memory 1. Depressing memory switch 2 will initiate a recall of the power driver seat position stored in memory 2. Depressing memory switch 1 and memory switch 2 simultaneously will initiate a recall of the power driver seat position stored in memory 3. ^ A remote transmitter can be used to recall previously set memory positions. Transmitters are manufactured with an assigned personality number (1, 2, or 3) and are so designated on the back of the transmitter. The transmitter assigned with personality 1 is capable of recalling memory position 1 only. Similarly, the personality 2 and 3 transmitters can recall only memory positions 2 and 3 respectively. ^ Memory recall occurs when the UNLOCK switch is depressed on the transmitter. The second depression of the UNLOCK switch, which unlocks passenger doors, does not initiate a memory recall. ^ A memory recall in progress does not prohibit the initiation of another memory recall; the most recently requested memory recall will be executed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Specifications Amplifier: Specifications Radio Amplifier Screws .......................................................................................................................................................... 2.1-2.9 N.m (18.7-25.8 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Amplifier Amplifier: Diagrams Amplifier Amplifier (C263) Amplifier (C264) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Amplifier > Page 9148 Amplifier (C284) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Amplifier > Page 9149 Amplifier: Diagrams Subwoofer Amplifier Subwoofer Amplifier (C442) Subwoofer Amplifier (C443) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 9150 Amplifier: Service and Repair REMOVAL NOTE: The climate control head has a top flange that extends behind the radio. The radio must be removed prior to removal of the climate control head. 1. Remove the radio chassis. 2. Position the climate control head aside. 1 Remove the screws. 2 Pull out the climate control head and position aside. 3. If equipped, remove the instrument panel floor duct panel. ^ Remove the two push clips and release the one expander clip. 4. If equipped, remove the center console assembly. 5. Remove the radio amplifier. 1 Remove the screws. 2 Disconnect the electrical connectors. ^ Remove the radio amplifier. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 9151 INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams CD Changer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 9156 CD Changer: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the mat at bottom of 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 CD changer and bracket. 4. Disconnect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 9157 5. Remove the screws. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9167 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9168 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9169 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9170 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9171 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9172 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9173 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9179 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9180 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9181 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9182 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9183 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9184 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9185 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 9186 Radio/Stereo Noise Filter: Specifications Radio Frequency Interference Suppression Bond to Bulkhead Screw .................................................................................... 2.1-2.9 N.m (18.7-25.8 Lb/In) Radio Frequency Interference Suppression Bond to Engine Nut ........................................................................................... 8.9-12.1 N.m (79.4-107 Lb/In) Radio Frequency Interference Suppression Bond Frame to Floorpan Screws ............................................................................... 4.5-6.3 N.m (40-56 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers Speaker: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9195 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9196 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9197 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9198 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9199 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9200 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9201 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Speaker: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9207 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9208 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9209 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9210 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9211 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9212 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9213 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 9214 Speaker: Specifications Radio Speaker Screws ........................................................................................................................ ........................................... 1.6-2.2 N.m (14-19 Lb/In) Subwoofer Enclosure Screws .................................................................................................................................................. 5.2-7.2 N.m (46.4-64.2 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 9215 Speaker: Description and Operation On all vehicles: ^ The rear radio speakers are located behind the rear door trim panels. ^ The front radio speakers are located behind the front door trim panels. ^ The subwoofer is located behind the RH quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Service and Repair Tape Player: Service and Repair 1. For best performance, it is recommended that the tape player be cleaned once for every 10 to 12 hours of playing time. The tape player should be cleaned using a Ford tape player cleaning cartridge, available at your Ford or Lincoln-Mercury Dealer. The use of other cleaning products is not recommended, as these products could cause damage to the player or cassette tapes. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9224 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Accessory Delay Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module Alarm Module: Locations Anti-Theft Transceiver Module Instrument Panel View The Anti Theft-Transceiver Module is located behind the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 9229 Alarm Module: Locations Passive Anti-Theft System Module Body View The Passive Anti-Theft System Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 9230 Alarm Module: Locations Remote Anti-Theft Personality Module Body Views Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 9231 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module Passive Anti-theft System Control Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 9234 Anti-theft Transceiver Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 9235 Alarm Module: Diagrams Remote Anti-Theft Personality Module Remote Anti-Theft Personality Module (C257) Remote Anti-Theft Personality Module (C256) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Key Programming - New Key With Diagnostic Tool Alarm Module: Service and Repair Key Programming - New Key With Diagnostic Tool NOTE: Before starting this procedure, make sure the key(s) you want to program have the correct mechanical cut. 1. Plug in NGS tester (requires V10 card or higher). ^ (Or use V8.0 or higher and select DN101 4V as vehicle). 2. Turn the key to RUN. 3. If the key is already programmed, the THEFT indicator proves out after two seconds or if the key is not programmed, the THEFT indicator flashes rapidly. 4. Enter PATS Function Test and select ERASE IGNITION KEY. 5. TEST in PROGRESS will display on the screen. If a programmed key is being used, all keys will be erased within five seconds. If a non programmed key is being used, erasing will take a minimum of eight minutes. 6. TEST COMPLETE will display on screen. All keys are now erased. 7. Turn the key to OFF, and then back to RUN. 8. THEFT indicator proves out after two seconds. 9. PATS key is now programmed. 10. Additional keys may be programmed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Key Programming - New Key With Diagnostic Tool > Page 9238 Alarm Module: Service and Repair Key Programming - New Key Without Diagnostic Tool NOTE: Before starting this procedure, make sure the key(s) you want to program have the correct mechanical cut. 1. Insert the non programmed key in the ignition and turn to RUN. 2. THEFT indicator flashes rapidly. 3. After 15 minutes of flashing, the THEFT indicator will stop flashing. 4. Within five minutes after the THEFT indicator has stopped flashing, turn the ignition key to OFF and back to RUN. 5. After 15 minutes of flashing, the THEFT indicator will stop flashing. 6. Within five minutes after the THEFT indicator has stopped flashing, turn the ignition key to OFF and back to RUN. 7. After 15 minutes of flashing, the THEFT indicator will stop flashing. 8. All originally programmed keys are now erased, and only the key in the ignition is programmed. 9. Additional keys may be programmed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Key Programming - New Key With Diagnostic Tool > Page 9239 Alarm Module: Service and Repair Key Programming - Spare Key NOTE: ^ Before starting this procedure, make sure the key(s) you want to program have the correct mechanical cut. ^ Performing this procedure does not erase existing programmed keys. 1. Insert the programmed key in the ignition. Turn to RUN. 2. THEFT indicator proves out after two seconds. 3. Remove the programmed key. 4. Within 15 seconds, insert the new key in the ignition and turn to RUN. 5. THEFT indicator proves out after two seconds. 6. The extra key is now programmed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Key Programming - New Key With Diagnostic Tool > Page 9240 Alarm Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the PATS module. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the PATS module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Key Programming - New Key With Diagnostic Tool > Page 9241 The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. ^ All vehicle keys must now be programmed. The first key will automatically program, and the additional keys should follow spare key programming. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Specifications Multifunction Electronic Control Module: Specifications GEM Screws ........................................................................................................................................ ........................................... 0.9-1.3 N.m (8-12 Lb/In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Specifications > Page 9245 Multifunction Electronic Control Module: Locations Instrument Panel View The Generic Electronic Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9248 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9249 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9250 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9251 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9252 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9253 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9254 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9255 Multifunction Electronic Control Module: Connector Views Generic Electronic Module (C239) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9256 Generic Electronic Module (C267) Generic Electronic Module (C240) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9257 Generic Electronic Module (C241) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9258 Multifunction Electronic Control Module: Electrical Diagrams Generic Electronic Module (Part 1 Of 5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9259 Generic Electronic module (Part 2 of 5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9260 Generic Electronic module (Part 3 of 5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9261 Generic Electronic module (Part 4 of 5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9262 Generic Electronic module (Part 5 of 5) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 9263 Multifunction Electronic Control Module: Description and Operation The Generic Electronic Module (GEM) constantly monitors its subsystems for concerns. If a concern is found in one of the subsystems, the GEM will record the concern in the form of a Diagnostic Trouble Code (DTC). The ignition switch position is very important to the GEM function. Often times, erratic or unexpected GEM function can be traced to problems with these GEM inputs. The GEM controls the following features: ^ Wipers/washers (front/rear). ^ Warning chimes. ^ Battery saver. ^ Illuminated entry and courtesy lamps. ^ Driver power window. ^ Accessory delay. ^ 4-wheel drive. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 9264 There are four modes of operation for the front wipers: speed dependent interval, slow, fast and wash. These modes are only active with the ignition switch in the RUN or ACC position. The two modes of operation for the rear wipers are interval and wash. These modes are only active with the ignition switch in the RUN or ACC positions and with both the liftgate and liftgate glass closed. The GEM controls five warning chimes and lamps: headlamps operating without the ignition on (chime only), door ajar (chime and lamp), key-in-ignition (chime only), driver seat safety belt warning (chime and lamp), and low washer fluid warning (chime and lamp). The battery saver feature removes extended interior lamp power drains from the battery. The GEM will keep power available for all interior lights and under hood lamp circuits for 40 minutes after the ignition switch is turned off. The GEM illuminates the interior courtesy lamps when any door is ajar. The GEM also provides illuminated entry when the unlock button is used to unlock the vehicle. The GEM illuminates the running board lamps when the interior lamps are activated (see courtesy lamps and illuminated entry description above) and the ignition switch is not in the RUN position. The delayed accessory feature provides power to the power windows for ten minutes after the ignition switch is moved from the RUN to the OFF position. If during this ten-minute period either front door is opened, the delayed accessory relay will be de-energized. This system is equipped with Automatic 4-Wheel Drive (A4WD). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Driver Seat Module Multifunction Electronic Control Module: Service and Repair Driver Seat Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the driver seat. 3. Disconnect the driver seat module electrical connectors. 4. Remove the screws from the driver seat module and release the module retainers from the module bracket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Driver Seat Module > Page 9267 Multifunction Electronic Control Module: Service and Repair Generic Electronic Module (GEM) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the steering column opening cover. 3. Remove the (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel. 4. Remove the (A) instrument panel fuse junction panel bolts and remove the (B) interior fuse junction panel nuts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Service and Repair > Driver Seat Module > Page 9268 5. Disconnect the (A) GEM electrical connectors from the (B) GEM. 6. Remove the screws and the GEM. INSTALLATION NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 1. To install, reverse the removal procedure. ^ Check for proper operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications RAP Module Nuts ................................................................................................................................ ......................................................... 7 Nm (62 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 9272 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 9273 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 9274 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Disconnect the C257 and C256 Remote Anti-theft Personality (RAP) module electrical connectors. 3. Remove the nuts and the RAP module. NOTE: On Expedition and later build Navigators, the antenna is internal to the module and must be replaced as an assembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 9275 strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9281 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9282 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9283 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9284 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9285 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9286 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9287 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9288 Trailer Connector: Electrical Diagrams Trailer/Camper Adapter (Part 1 Of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9289 Trailer/Camper Adapter (Part 2 Of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9290 Trailer/Camper Adapter (Part 3 Of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement Technical Service Bulletin # 00S05 Date: 000501 Recall - Trailer Hitch Hardware Replacement 00S05 SAFETY RECALL All 1997-2000 Model Year Expedition and Navigator with Trailer Hitch Package - Hitch Attachment ^ Original - May, 2000 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Notification Letter ^ Supplement # 1 - May, 2000 Aftermarket Hitch Kits and Existing Dealer Stock Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9299 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9300 Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instruction on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Attachment II Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9301 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts wilt not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information shown. SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III AFFECTED VEHICLES: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9302 CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9303 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9304 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9305 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9306 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9307 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9308 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9309 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9310 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT (I )Immediately contact any affected owner whose name is not on the list Give the owner a copy of the Owner Letter and schedule a service date. This contact includes owners who have purchased aftermarket hitch kit # F75Z-17D826-AE. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9311 REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Supplement # 1 - Attachment II LABOR ALLOWANCES PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9312 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown above. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information above: SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. (I )REWORK OF EXISTING DEALER STOCK Call the Recall Hotline at 1-800-325-5621,to obtain instructions for reworking existing stock of Trailer Hitch Kits (part # F75Z-17D826-AE). NOTE: The Recall Hotline will provide new hardware and kit installation instructions.When you rework dealer stock, please make sure these revised instructions (with new torque specifications) are included in the kit. DEALER PRICE For latest prices, refer to: ^ DOESII ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Supplement # 1 - Attachment III HITCH ATTACHING FASTENER REPLACEMENT AFFECTED VEHICLES: CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9313 SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9314 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch. ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9315 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9316 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9317 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9318 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > NHTSA00V073000 > Mar > 00 > Recall 00V073000: Trailer Hitch Attaching Bolts Loose Trailer Hitch: Recalls Recall 00V073000: Trailer Hitch Attaching Bolts Loose Vehicle Description: Multi-purpose vehicles. The trailer hitch assembly to the frame attaching bolts could lose the clamp load. The trailer hitch could then separate from the vehicle. Dealers will replace the trailer hitch mounting bolts and nut plates. Owner notification began May 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1997 FORD TRUCK EXPEDITION 1997 LINCOLN TRUCK NAVIGATOR 1998 FORD TRUCK EXPEDITION 1998 LINCOLN TRUCK NAVIGATOR 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR 2000 FORD TRUCK EXPEDITION 2000 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement Technical Service Bulletin # 00S05 Date: 000501 Recall - Trailer Hitch Hardware Replacement 00S05 SAFETY RECALL All 1997-2000 Model Year Expedition and Navigator with Trailer Hitch Package - Hitch Attachment ^ Original - May, 2000 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Notification Letter ^ Supplement # 1 - May, 2000 Aftermarket Hitch Kits and Existing Dealer Stock Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9328 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9329 Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instruction on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Attachment II Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9330 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts wilt not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information shown. SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III AFFECTED VEHICLES: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9331 CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9332 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9333 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9334 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9335 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9336 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9337 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9338 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9339 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT (I )Immediately contact any affected owner whose name is not on the list Give the owner a copy of the Owner Letter and schedule a service date. This contact includes owners who have purchased aftermarket hitch kit # F75Z-17D826-AE. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9340 REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Supplement # 1 - Attachment II LABOR ALLOWANCES PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9341 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown above. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information above: SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. (I )REWORK OF EXISTING DEALER STOCK Call the Recall Hotline at 1-800-325-5621,to obtain instructions for reworking existing stock of Trailer Hitch Kits (part # F75Z-17D826-AE). NOTE: The Recall Hotline will provide new hardware and kit installation instructions.When you rework dealer stock, please make sure these revised instructions (with new torque specifications) are included in the kit. DEALER PRICE For latest prices, refer to: ^ DOESII ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Supplement # 1 - Attachment III HITCH ATTACHING FASTENER REPLACEMENT AFFECTED VEHICLES: CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9342 SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9343 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch. ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9344 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9345 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9346 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 9347 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > NHTSA00V073000 > Mar > 00 > Recall 00V073000: Trailer Hitch Attaching Bolts Loose Trailer Hitch: All Technical Service Bulletins Recall 00V073000: Trailer Hitch Attaching Bolts Loose Vehicle Description: Multi-purpose vehicles. The trailer hitch assembly to the frame attaching bolts could lose the clamp load. The trailer hitch could then separate from the vehicle. Dealers will replace the trailer hitch mounting bolts and nut plates. Owner notification began May 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1997 FORD TRUCK EXPEDITION 1997 LINCOLN TRUCK NAVIGATOR 1998 FORD TRUCK EXPEDITION 1998 LINCOLN TRUCK NAVIGATOR 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR 2000 FORD TRUCK EXPEDITION 2000 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9356 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9357 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9358 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9359 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9360 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9361 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9362 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9363 Trailer Lamps: Electrical Diagrams Trailer/Camper Adapter (Part 1 Of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9364 Trailer/Camper Adapter (Part 2 Of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9365 Trailer/Camper Adapter (Part 3 Of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis Trailer Lamps: Flow of Diagnosis 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Blown fuse(s) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9368 Trailer Lamps: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Blown fuse(s) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9369 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9370 Trailer Lamps: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9371 AD1 - AD2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9372 AE1 - AE2 AF Individual Trailer Lamp Inop - RH Turn/Stop/Hazard Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9373 AF1 - AF2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9374 AF3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9375 AF4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9376 AF5 AG Individual Trailer Lamp Inop - LH Turn/Stop/Hazard Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9377 AG1 - AG2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9378 AG3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9379 AG4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9380 AG5 AH Trailer Parking Lamps Inop AH1 - AH2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9381 AH3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9382 AH4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9383 AH5 - AH6 AJ Trailer Backup Lamps Inop Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9384 AJ1 - AJ2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9385 AJ3 - AJ4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9386 AJ5 - AJ6 AK Trailer Battery Charging Inop Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9387 AK1 - AK2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9388 AK3- AK4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9389 AK5 - AK6 AL Trailer Electric Brakes Inop Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9390 AL1 - AL2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9391 AL3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9392 AL4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9393 AL5 - AL6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9394 AL7 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9395 73 Digital Multimeter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay Trailer Lighting Relay: Locations Trailer Tow Backup Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 9400 The Trailer Tow Backup Lamp Relay is located in the Power Distribution Box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 9401 Trailer Lighting Relay: Locations Trailer Tow Battery Charge Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 9402 The Trailer Tow Backup Lamp Relay is located in the Power Distribution Box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 9403 Trailer Lighting Relay: Locations Trailer Tow Left Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 9404 The Trailer Tow Backup Lamp Relay is located in the Power Distribution Box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 9405 Trailer Lighting Relay: Locations Trailer Tow Right Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 9406 The Trailer Tow Backup Lamp Relay is located in the Power Distribution Box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9411 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9412 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9413 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9414 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9415 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9416 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9417 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9418 Trailer Connector: Electrical Diagrams Trailer/Camper Adapter (Part 1 Of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9419 Trailer/Camper Adapter (Part 2 Of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9420 Trailer/Camper Adapter (Part 3 Of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations Trip Computer: Locations Body View The Overhead Trip Computer Module is located in front of the overhead console. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations > Page 9424 Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Technical Service Bulletins > Customer Interest for Auxiliary Step / Running Board: > 98-13-15 > Jul > 98 > Running Boards - Too Narrow When Exiting Vehicle Auxiliary Step / Running Board: Customer Interest Running Boards - Too Narrow When Exiting Vehicle Article No. 98-13-15 07/06/98 RUNNING BOARDS - PERCEPTION OF RUNNING BOARDS BEING TOO NARROW WHEN EXITING VEHICLE - SERVICE TIP LIGHT TRUCK: 1997-98 EXPEDITION ISSUE The running boards may be too narrow for some customers when exiting the vehicle. ACTION A service kit is available to move the running board outboard 25 mm (1"). Refer to the Instruction Sheet (F85B-16450-AB) included in the kit for installation procedures. PART NUMBER PART NAME F85Z-16450-AB Running Board Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 190000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Technical Service Bulletins > By Symptom for Auxiliary Step / Running Board: > 98-13-15 > Jul > 98 > Running Boards - Too Narrow When Exiting Vehicle Auxiliary Step / Running Board: By Symptom Running Boards - Too Narrow When Exiting Vehicle Article No. 98-13-15 07/06/98 RUNNING BOARDS - PERCEPTION OF RUNNING BOARDS BEING TOO NARROW WHEN EXITING VEHICLE - SERVICE TIP LIGHT TRUCK: 1997-98 EXPEDITION ISSUE The running boards may be too narrow for some customers when exiting the vehicle. ACTION A service kit is available to move the running board outboard 25 mm (1"). Refer to the Instruction Sheet (F85B-16450-AB) included in the kit for installation procedures. PART NUMBER PART NAME F85Z-16450-AB Running Board Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 190000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Step / Running Board: > 98-13-15 > Jul > 98 > Running Boards - Too Narrow When Exiting Vehicle Auxiliary Step / Running Board: All Technical Service Bulletins Running Boards - Too Narrow When Exiting Vehicle Article No. 98-13-15 07/06/98 RUNNING BOARDS - PERCEPTION OF RUNNING BOARDS BEING TOO NARROW WHEN EXITING VEHICLE - SERVICE TIP LIGHT TRUCK: 1997-98 EXPEDITION ISSUE The running boards may be too narrow for some customers when exiting the vehicle. ACTION A service kit is available to move the running board outboard 25 mm (1"). Refer to the Instruction Sheet (F85B-16450-AB) included in the kit for installation procedures. PART NUMBER PART NAME F85Z-16450-AB Running Board Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 190000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > Customer Interest for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining Technical Service Bulletin # 98-1-13 Date: 980119 Bumper - Rust Staining Article No. 98-1-13 01/19/98 BUMPER - RUST STAIN - EDGES OF CENTER VENT AND FOG LAMP OPENINGS LIGHT TRUCK: 1990-96 BRONCO 1990-97 F-250 HD, F-350 1997 ECONOLINE, EXPLORER 1997-98 EXPEDITION, F-150, F-250 LD ISSUE: Red rust stains on the edges of the bumper center vent and fog lamp openings may appear on some vehicles. ACTION: Apply Super Seal Anti-Corrosion Compound to the affected areas of the bumper. Refer to the following Service Procedures for details. NOTE: USE A PROTECTIVE GLOVE FOR APPLYING BOTH THE CUSTOM BRIGHT METAL CLEANER (8A-19522-A) AND THE SUPER SEAL ANTI-CORROSION COMPOUND (F3AZ-19515-SA). For each of the specific vehicle procedures found in this TSB article, be sure the following 3 steps are done: 1. Clean the red rust stain from the inside and chrome surface of the bumper. 2. Paint the edge of openings and at least 25 mm (1") area around the inside of the bumper vent and fog lamp openings. 3. Spray around the top cover attachment holes/slots. PART NUMBER PART NAME F3AZ-19515-SA Super Seal Anti-Corrosion compound 8A-19522-A Custom Bright Metal cleaner OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980113A Apply Sealer - Front 0.8 Hr. Bumper - 1997-98 Expedition/F-150-250 LD 4X4 Under 8500 Lbs GVW 980113B Apply Sealer - Front 0.5 Hr. Bumper - 1997-98 F-150-250 LD 4X2 Under 8500 Lbs GVW 980113C Apply Sealer - Rear 0.4 Hr. Bumper - 1997-98 F-150-250 LD 4X2/4X4 Under 8500 Lbs GVW 980113D Apply Sealer - Front 0.5 Hr. Bumper - 1990-97 F-250 HD/F-350/Bronco 980113E Apply Sealer - Rear 0.4 Hr. Bumper - 1990-97 F-250 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > Customer Interest for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 9452 HD/F-350/Bronco 980113F Apply Sealer - Rear 0.6 Hr. Bumper - 1997-98 Expedition 980113G Apply Sealer - Front 0.5 Hr. Bumper - 1997 Explorer XLT/Eddie Bauer 980113H Apply Sealer - Rear 0.5 Hr. Bumper - 1997 Explorer 9801131 Apply Sealer - Front 0.5 Hr. Bumper - 1997 Econoline DEALER CODING CONDITION BASIC PART NO. CODE 17757 68 OASIS CODES: 106000 1997-98 Expedition/F-150/250 LD 4X4 Frnt. Bumper 1997-98 EXPEDITION AND F-150/250 LD 4X4 FRONT BUMPER 1. Turn off air suspension if applicable. 2. Hoist vehicle until bumper is at working level. 3. Remove the fog lamps or fog lamp blanks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > Customer Interest for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 9453 4. Mask the front face of the center at air opening and both fog lamp openings (Figure 1). 5. Disconnect fog lamp wiring and block heater wires from the bumper. 6. Disconnect the three (3) push pins for the splash guard. 7. Clean excessive dirt from inside and outside the bumper. 8. Spray the edges of the three (3) openings with Super Seal Anti-Corrosion Compound. 9. Remove the tape from the fog lamp openings so as not to get the Super Seal Anti-Corrosion Compound on the fog lamps during reinstallation. 10. Reinstall the fog lamps/fog lamp blanks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > Customer Interest for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 9454 11. Plug in fog lamp wiring and push pins for the block heater connector and lower valance push pins. 12. Lower vehicle and turn on air suspension if so equipped. 13. Clean vent and fog lamp openings as needed. 1997-98 F-150/250 LD 4X2 Front Bumper 1997-98 F-150/250 LD 4X2 FRONT BUMPER 1. Turn off air suspension it applicable. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. 4. Remove the five (5) push pins to the radiator support. 5. Spray the edges of the air intake opening and the bumper cover retainer openings and drain holes with Super Seal Anti-Corrosion Compound. 6. Reinstall the push pins and remove the tape. 7. Lower vehicle and turn on air suspension if so equipped. 8. Clean off overspray as needed. 1997-98 F-150/250 LD Rear Bumper (4X2/4X4) 1997-98 F-150/250 LD REAR BUMPER (4X2 AND 4X4) 1. Turn off air suspension if applicable. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. 4. Spray the back of the bumper from underneath the vehicle. Make sure to spray the license plate lights, openings, and the bumper pad retaining holes with Super Seal Anti-Corrosion Compound. 5. Lower vehicle and turn on air suspension if so equipped. 6. Clean off overspray as needed. 1990-97 F-250 HD/F-350/Bronco Frnt./Rear Bumper 1990-97 F-250 HD/F-350/BRONCO - FRONT BUMPER 1. Hoist vehicle until bumper is at working level. 2. Remove the lower valance out of the way to allow access to inside of front bumper. 3. Clean excessive dirt from inside and outside the bumper. 4. Tape license plate bolt holes. 5. Spray the edge of the opening and the bolt opening area including the license plate lights bracket holes with Super Seal Anti-Corrosion Compound. 6. Reinstall lower valance. 7. Remove protective tape. 8. Lower vehicle. 9. Clean off overspray as needed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > Customer Interest for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 9455 1990-97 F-250 HD/F-350/BRONCO - REAR BUMPER 1. Install newspaper between the tailgate and the bumper top cover to prevent spray on the tailgate. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. 4. Spray the back side of the bumper from underneath the vehicle. Make sure to spray the license plate light opening, and the bolt mounting areas above the bumper mounting bracket to prevent water from leaking to the front from the back side. Also spray the bumper pad retaining holes. 5. Lower vehicle. 6. Remove paper and clean off overspray as needed. 1997-98 Expedition - Rear Bumper 1997-98 EXPEDITION - REAR BUMPER 1. Turn off air suspension, if equipped. 2. Remove spare tire. 3. Hoist vehicle until bumper is at working level. 4. Clean excessive dirt from inside and outside the bumper. 5. Spray the back of the bumper from underneath the vehicle with Super Seal Anti-Corrosion Compound. 6. Lower vehicle and turn on air suspension if so equipped. 7. Reinstall spare tire. 8. Clean off overspray as needed. 1997 Explorer XLT/Eddie Bauer - Frnt. Bumper 1997 EXPLORER XLT/EDDIE BAUER - FRONT BUMPER 1. Hoist vehicle until bumper is at working level. 2. Remove the four (4) screws and two (2) push pins from the lower valance of the radiator and remove valance. 3. Tape the air intake openings in the bumper (Figure 1). Removal of the license plate bracket is not required. 4. Clean excessive dirt from inside and outside the bumper. 5. Spray the edge of the air intake opening and the bumper cover retainer openings with Super Seal Anti-Corrosion Compound. 6. Remove tape and reinstall the radiator lower valance. 7. Lower vehicle. 8. Clean off overspray as needed. 1997 Explorer - Rear Bumper 1997 EXPLORER - REAR BUMPER 1. Remove spare tire. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. A light amount will not affect the effectiveness of the Super Seal Anti-Corrosion Compound. 4. Spray the back of the bumper with Super Seal Anti-Corrosion Compound paying close attention to the areas around the license plate lights and the Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > Customer Interest for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 9456 top cover retaining tab openings in the bumper. These are the areas that let the back side rust bleed to the front of the bumper and cause stain. 5. Lower vehicle. 6. Reinstall spare tire. 7. Clean off overspray as needed. 1997 Econoline - Front Bumper 1997 ECONOLINE - FRONT BUMPER 1. Hoist vehicle until bumper is at working level. 2. Remove the two (2) lower valance push pins and remove valance. 3. Tape the air intake opening. 4. Clean excessive dirt from inside and outside the bumper. 5. Spray the edge of the air intake opening and the bumper cover retainer openings with Super Seal Anti-Corrosion Compound. 6. Remove tape and reinstall the lower valance push pins. 7. Lower vehicle. 8. Clean off overspray as needed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining Technical Service Bulletin # 98-1-13 Date: 980119 Bumper - Rust Staining Article No. 98-1-13 01/19/98 BUMPER - RUST STAIN - EDGES OF CENTER VENT AND FOG LAMP OPENINGS LIGHT TRUCK: 1990-96 BRONCO 1990-97 F-250 HD, F-350 1997 ECONOLINE, EXPLORER 1997-98 EXPEDITION, F-150, F-250 LD ISSUE: Red rust stains on the edges of the bumper center vent and fog lamp openings may appear on some vehicles. ACTION: Apply Super Seal Anti-Corrosion Compound to the affected areas of the bumper. Refer to the following Service Procedures for details. NOTE: USE A PROTECTIVE GLOVE FOR APPLYING BOTH THE CUSTOM BRIGHT METAL CLEANER (8A-19522-A) AND THE SUPER SEAL ANTI-CORROSION COMPOUND (F3AZ-19515-SA). For each of the specific vehicle procedures found in this TSB article, be sure the following 3 steps are done: 1. Clean the red rust stain from the inside and chrome surface of the bumper. 2. Paint the edge of openings and at least 25 mm (1") area around the inside of the bumper vent and fog lamp openings. 3. Spray around the top cover attachment holes/slots. PART NUMBER PART NAME F3AZ-19515-SA Super Seal Anti-Corrosion compound 8A-19522-A Custom Bright Metal cleaner OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980113A Apply Sealer - Front 0.8 Hr. Bumper - 1997-98 Expedition/F-150-250 LD 4X4 Under 8500 Lbs GVW 980113B Apply Sealer - Front 0.5 Hr. Bumper - 1997-98 F-150-250 LD 4X2 Under 8500 Lbs GVW 980113C Apply Sealer - Rear 0.4 Hr. Bumper - 1997-98 F-150-250 LD 4X2/4X4 Under 8500 Lbs GVW 980113D Apply Sealer - Front 0.5 Hr. Bumper - 1990-97 F-250 HD/F-350/Bronco 980113E Apply Sealer - Rear 0.4 Hr. Bumper - 1990-97 F-250 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 9462 HD/F-350/Bronco 980113F Apply Sealer - Rear 0.6 Hr. Bumper - 1997-98 Expedition 980113G Apply Sealer - Front 0.5 Hr. Bumper - 1997 Explorer XLT/Eddie Bauer 980113H Apply Sealer - Rear 0.5 Hr. Bumper - 1997 Explorer 9801131 Apply Sealer - Front 0.5 Hr. Bumper - 1997 Econoline DEALER CODING CONDITION BASIC PART NO. CODE 17757 68 OASIS CODES: 106000 1997-98 Expedition/F-150/250 LD 4X4 Frnt. Bumper 1997-98 EXPEDITION AND F-150/250 LD 4X4 FRONT BUMPER 1. Turn off air suspension if applicable. 2. Hoist vehicle until bumper is at working level. 3. Remove the fog lamps or fog lamp blanks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 9463 4. Mask the front face of the center at air opening and both fog lamp openings (Figure 1). 5. Disconnect fog lamp wiring and block heater wires from the bumper. 6. Disconnect the three (3) push pins for the splash guard. 7. Clean excessive dirt from inside and outside the bumper. 8. Spray the edges of the three (3) openings with Super Seal Anti-Corrosion Compound. 9. Remove the tape from the fog lamp openings so as not to get the Super Seal Anti-Corrosion Compound on the fog lamps during reinstallation. 10. Reinstall the fog lamps/fog lamp blanks. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 9464 11. Plug in fog lamp wiring and push pins for the block heater connector and lower valance push pins. 12. Lower vehicle and turn on air suspension if so equipped. 13. Clean vent and fog lamp openings as needed. 1997-98 F-150/250 LD 4X2 Front Bumper 1997-98 F-150/250 LD 4X2 FRONT BUMPER 1. Turn off air suspension it applicable. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. 4. Remove the five (5) push pins to the radiator support. 5. Spray the edges of the air intake opening and the bumper cover retainer openings and drain holes with Super Seal Anti-Corrosion Compound. 6. Reinstall the push pins and remove the tape. 7. Lower vehicle and turn on air suspension if so equipped. 8. Clean off overspray as needed. 1997-98 F-150/250 LD Rear Bumper (4X2/4X4) 1997-98 F-150/250 LD REAR BUMPER (4X2 AND 4X4) 1. Turn off air suspension if applicable. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. 4. Spray the back of the bumper from underneath the vehicle. Make sure to spray the license plate lights, openings, and the bumper pad retaining holes with Super Seal Anti-Corrosion Compound. 5. Lower vehicle and turn on air suspension if so equipped. 6. Clean off overspray as needed. 1990-97 F-250 HD/F-350/Bronco Frnt./Rear Bumper 1990-97 F-250 HD/F-350/BRONCO - FRONT BUMPER 1. Hoist vehicle until bumper is at working level. 2. Remove the lower valance out of the way to allow access to inside of front bumper. 3. Clean excessive dirt from inside and outside the bumper. 4. Tape license plate bolt holes. 5. Spray the edge of the opening and the bolt opening area including the license plate lights bracket holes with Super Seal Anti-Corrosion Compound. 6. Reinstall lower valance. 7. Remove protective tape. 8. Lower vehicle. 9. Clean off overspray as needed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 9465 1990-97 F-250 HD/F-350/BRONCO - REAR BUMPER 1. Install newspaper between the tailgate and the bumper top cover to prevent spray on the tailgate. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. 4. Spray the back side of the bumper from underneath the vehicle. Make sure to spray the license plate light opening, and the bolt mounting areas above the bumper mounting bracket to prevent water from leaking to the front from the back side. Also spray the bumper pad retaining holes. 5. Lower vehicle. 6. Remove paper and clean off overspray as needed. 1997-98 Expedition - Rear Bumper 1997-98 EXPEDITION - REAR BUMPER 1. Turn off air suspension, if equipped. 2. Remove spare tire. 3. Hoist vehicle until bumper is at working level. 4. Clean excessive dirt from inside and outside the bumper. 5. Spray the back of the bumper from underneath the vehicle with Super Seal Anti-Corrosion Compound. 6. Lower vehicle and turn on air suspension if so equipped. 7. Reinstall spare tire. 8. Clean off overspray as needed. 1997 Explorer XLT/Eddie Bauer - Frnt. Bumper 1997 EXPLORER XLT/EDDIE BAUER - FRONT BUMPER 1. Hoist vehicle until bumper is at working level. 2. Remove the four (4) screws and two (2) push pins from the lower valance of the radiator and remove valance. 3. Tape the air intake openings in the bumper (Figure 1). Removal of the license plate bracket is not required. 4. Clean excessive dirt from inside and outside the bumper. 5. Spray the edge of the air intake opening and the bumper cover retainer openings with Super Seal Anti-Corrosion Compound. 6. Remove tape and reinstall the radiator lower valance. 7. Lower vehicle. 8. Clean off overspray as needed. 1997 Explorer - Rear Bumper 1997 EXPLORER - REAR BUMPER 1. Remove spare tire. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. A light amount will not affect the effectiveness of the Super Seal Anti-Corrosion Compound. 4. Spray the back of the bumper with Super Seal Anti-Corrosion Compound paying close attention to the areas around the license plate lights and the Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 9466 top cover retaining tab openings in the bumper. These are the areas that let the back side rust bleed to the front of the bumper and cause stain. 5. Lower vehicle. 6. Reinstall spare tire. 7. Clean off overspray as needed. 1997 Econoline - Front Bumper 1997 ECONOLINE - FRONT BUMPER 1. Hoist vehicle until bumper is at working level. 2. Remove the two (2) lower valance push pins and remove valance. 3. Tape the air intake opening. 4. Clean excessive dirt from inside and outside the bumper. 5. Spray the edge of the air intake opening and the bumper cover retainer openings with Super Seal Anti-Corrosion Compound. 6. Remove tape and reinstall the lower valance push pins. 7. Lower vehicle. 8. Clean off overspray as needed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems Technical Service Bulletin # 98-9-13 Date: 980511 Body/Frame - Water Leaks Causing Electrical Problems Article No. 98-9-13 05/11/98 ^ WATER LEAKS - VARIOUS AREAS OF VEHICLE ^ ELECTRICAL - ACCESSORIES FUNCTIONING IMPROPERLY DUE TO WATER LEAKS ^ LAMPS - WARNING LAMPS ILLUMINATED DUE TO WATER LEAKS LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to add F-150, F-250 LD, and Navigator vehicles, and to revise the text and art accordingly. ISSUE Water leaks in various areas of the vehicle as identified below may be causing electrical concerns such as: ^ Warning lamps illuminating, and/or ^ Improper wiper operation, and/or ^ Improper function of electrical accessories The water leaks may be caused by sealer skips, unseated grommets, and/or clogged drain tubes. ACTION Repair the water leaks. Refer to the following Service Procedures for details on: ^ Windshield Leaks ^ Cowl Top Leaks ^ Cowl Side-to-Door Opening Panel Leaks ^ Cowl Side-to-Dash Panel Leaks ^ Moon roof Leaks ^ Grommets The following procedures may include using a seam sealer for repairs. Recommended seam sealers are: Company Part Name Phone Number 3M Ultrapro Seam Sealer (612) 733-5547 - US Kent Uniweld Seam Sealer (800) 654-6333 - US (800) 663-2800 - Canada OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-19-15 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9475 980913A Windshield Leaks Service 0.5 Hr. Procedure 980913B Additional Time If Leaf 0.4 Hr. Screen Must Be Removed (Used With Operation A) 980913C Cowl Top Leaks Service 1.3 Hrs. Procedure 980913D Cowl Side-To-Door 1.9 Hrs. Opening Panel Leaks Service Procedure 980913E Cowl Side-To-Dash Panel 0.4 Hr. Leaks Service Procedure 980913F Moonroof Leaks Service 0.4 Hr. Procedure 980913G Grommets Service 0.4 Hr. Procedure DEALER CODING CONDITION BASIC PART NO. CODE 18812 GROMMET(S) LEAKS 68 7801610 COWL TOP LEAKS (DASH PANEL) 68 7802012 COWL TOP LEAKS (OUTER) 68 7802018 COWL SIDE TO-DASH PANEL LEAKS 68 7802039 COWL SIDE-TO-DOOR OPENING PANEL LEAKS 68 7803100 WINDSHIELD LEAKS 68 78502C53 MOON ROOF LEAKS 68 OASIS CODES: 110000,190000, 202000, 203000, 205000, 206000 Windshield Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9476 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9477 Refer To Figures 1, 2, and 3 1. Remove A-pillar mouldings, rocker panel scuff plates, and cowl lower scuff plates. Refer to the appropriate Workshop Manual, Section 501-05. 2. Apply a water hose at the bottom center of the windshield and slowly move outboard at a rate of 305 mm (1 foot) per 15-20 seconds. Then move up one side, inboard along top of header to the center. Lift the moulding at top of windshield to allow water to pass through windshield moulding. NOTE A NARROW NYLON TIP ON THE END OF THE HOSE WILL ALLOW THE OPERATOR TO EASILY SLIDE THE TIP UNDER THE MOULDING AND SLOWLY MOVE IT ALONG THE INSIDE SURFACE. 3. To determine if water is entering, have an observer use a flashlight to watch for water as the hose is being moved. The observer should start looking at the dash back panel by pulling back the dash insulator pad above the water location. 4. If a leak is detected, document the location and path for future reference. 5. Fill any voids with pumpable Butyl Sealer. NOTE TO REPAIR WATER LEAKS FOUND AT THE BASE OF THE WINDSHIELD, THE LEAF SCREEN MUST FIRST BE REMOVED. Cowl Top Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9478 Refer To Figure 4 1. Remove the leaf screen by referring to the appropriate Workshop Manual, Section 501-02. 2. Spray water into cowl top-to-dash panel seam. Spray for up to 20 minutes. 3. Inspect the inner dash panel for water intrusion, starting at the bottom of the cowl area. 4. With the trim rocker cover and kick plate removed, pull back carpet and inspect for water. 5. If no water is found, look in the area of the cross car beam and/or lower windshield "VIN tag" area. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9479 6. Seal inner cowl with seam sealer. Cowl Side-to-Door Opening Panel Leaks Service Procedure Refer To Figure 5 1. Remove the left front tire. 2. Remove the inner fender splash shield from the left front fender. Refer to the appropriate Workshop Manual, Section 501-02, for details. 3. Remove the grille by referring to the Workshop Manual, Section 501-08. 4. Remove the left front fender by referring to the Workshop Manual, Section 501-02. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9480 5. Test with water. 6. Apply seam sealer along the interface between the cowl and the dash panel. This area can be reached through the access hole located near the top hinge for the front door. 7. Reassemble in reverse order. 8. Apply paint protection to fender bolts. Cowl Side-to-Dash Panel Leaks Service Procedure Refer To Figure 6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9481 1. Remove rocker cover and lower scuff panel by referring to the appropriate Workshop Manual, Section 501-05. 2. Inspect dash panel-to-cowl side inner sealer for skips and/or missing sealer. 3. Test with water at the top of the cowl/leaf screen area and inspect the vehicle for water entry. 4. Apply seam sealer along the interface between the cowl, dash, and floor panel. Moonroof Leaks Service Procedure Refer To Figure 7 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9482 1. Before beginning any diagnosis, contact the Webasto Tech Hotline at (800) 995-5911 Monday-Friday, 9AM-6PM EST. 2. Cycle moonroof to open position. 3. Check for proper drain tube action by pouring approximately 1.8L (6 oz) of water into trough at each side. 4. If tubes appear to be draining properly, remove the interior A-pillar trim and sun visors. Refer to the appropriate Workshop Manual, Section 501-05. 5. Pull down the headliner slightly and inspect moonroof drain tubes for kinks and/or twists. The drain tubes must be free from any bends or obstruction of water flow. 6. Straighten or cut drain tubes to proper length to allow for free draining. Grommets Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9483 Refer To Figure 8 1. Check for missing or improperly seated grommets in the following areas: ^ Antenna grommet on passenger side cowl ^ Park brake cable grommet on driver side cowl ^ Overall instrument panel grommets 2. Reseat any loose grommets or replace any missing grommets. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems Technical Service Bulletin # 98-9-13 Date: 980511 Body/Frame - Water Leaks Causing Electrical Problems Article No. 98-9-13 05/11/98 ^ WATER LEAKS - VARIOUS AREAS OF VEHICLE ^ ELECTRICAL - ACCESSORIES FUNCTIONING IMPROPERLY DUE TO WATER LEAKS ^ LAMPS - WARNING LAMPS ILLUMINATED DUE TO WATER LEAKS LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to add F-150, F-250 LD, and Navigator vehicles, and to revise the text and art accordingly. ISSUE Water leaks in various areas of the vehicle as identified below may be causing electrical concerns such as: ^ Warning lamps illuminating, and/or ^ Improper wiper operation, and/or ^ Improper function of electrical accessories The water leaks may be caused by sealer skips, unseated grommets, and/or clogged drain tubes. ACTION Repair the water leaks. Refer to the following Service Procedures for details on: ^ Windshield Leaks ^ Cowl Top Leaks ^ Cowl Side-to-Door Opening Panel Leaks ^ Cowl Side-to-Dash Panel Leaks ^ Moon roof Leaks ^ Grommets The following procedures may include using a seam sealer for repairs. Recommended seam sealers are: Company Part Name Phone Number 3M Ultrapro Seam Sealer (612) 733-5547 - US Kent Uniweld Seam Sealer (800) 654-6333 - US (800) 663-2800 - Canada OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-19-15 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9489 980913A Windshield Leaks Service 0.5 Hr. Procedure 980913B Additional Time If Leaf 0.4 Hr. Screen Must Be Removed (Used With Operation A) 980913C Cowl Top Leaks Service 1.3 Hrs. Procedure 980913D Cowl Side-To-Door 1.9 Hrs. Opening Panel Leaks Service Procedure 980913E Cowl Side-To-Dash Panel 0.4 Hr. Leaks Service Procedure 980913F Moonroof Leaks Service 0.4 Hr. Procedure 980913G Grommets Service 0.4 Hr. Procedure DEALER CODING CONDITION BASIC PART NO. CODE 18812 GROMMET(S) LEAKS 68 7801610 COWL TOP LEAKS (DASH PANEL) 68 7802012 COWL TOP LEAKS (OUTER) 68 7802018 COWL SIDE TO-DASH PANEL LEAKS 68 7802039 COWL SIDE-TO-DOOR OPENING PANEL LEAKS 68 7803100 WINDSHIELD LEAKS 68 78502C53 MOON ROOF LEAKS 68 OASIS CODES: 110000,190000, 202000, 203000, 205000, 206000 Windshield Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9490 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9491 Refer To Figures 1, 2, and 3 1. Remove A-pillar mouldings, rocker panel scuff plates, and cowl lower scuff plates. Refer to the appropriate Workshop Manual, Section 501-05. 2. Apply a water hose at the bottom center of the windshield and slowly move outboard at a rate of 305 mm (1 foot) per 15-20 seconds. Then move up one side, inboard along top of header to the center. Lift the moulding at top of windshield to allow water to pass through windshield moulding. NOTE A NARROW NYLON TIP ON THE END OF THE HOSE WILL ALLOW THE OPERATOR TO EASILY SLIDE THE TIP UNDER THE MOULDING AND SLOWLY MOVE IT ALONG THE INSIDE SURFACE. 3. To determine if water is entering, have an observer use a flashlight to watch for water as the hose is being moved. The observer should start looking at the dash back panel by pulling back the dash insulator pad above the water location. 4. If a leak is detected, document the location and path for future reference. 5. Fill any voids with pumpable Butyl Sealer. NOTE TO REPAIR WATER LEAKS FOUND AT THE BASE OF THE WINDSHIELD, THE LEAF SCREEN MUST FIRST BE REMOVED. Cowl Top Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9492 Refer To Figure 4 1. Remove the leaf screen by referring to the appropriate Workshop Manual, Section 501-02. 2. Spray water into cowl top-to-dash panel seam. Spray for up to 20 minutes. 3. Inspect the inner dash panel for water intrusion, starting at the bottom of the cowl area. 4. With the trim rocker cover and kick plate removed, pull back carpet and inspect for water. 5. If no water is found, look in the area of the cross car beam and/or lower windshield "VIN tag" area. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9493 6. Seal inner cowl with seam sealer. Cowl Side-to-Door Opening Panel Leaks Service Procedure Refer To Figure 5 1. Remove the left front tire. 2. Remove the inner fender splash shield from the left front fender. Refer to the appropriate Workshop Manual, Section 501-02, for details. 3. Remove the grille by referring to the Workshop Manual, Section 501-08. 4. Remove the left front fender by referring to the Workshop Manual, Section 501-02. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9494 5. Test with water. 6. Apply seam sealer along the interface between the cowl and the dash panel. This area can be reached through the access hole located near the top hinge for the front door. 7. Reassemble in reverse order. 8. Apply paint protection to fender bolts. Cowl Side-to-Dash Panel Leaks Service Procedure Refer To Figure 6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9495 1. Remove rocker cover and lower scuff panel by referring to the appropriate Workshop Manual, Section 501-05. 2. Inspect dash panel-to-cowl side inner sealer for skips and/or missing sealer. 3. Test with water at the top of the cowl/leaf screen area and inspect the vehicle for water entry. 4. Apply seam sealer along the interface between the cowl, dash, and floor panel. Moonroof Leaks Service Procedure Refer To Figure 7 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9496 1. Before beginning any diagnosis, contact the Webasto Tech Hotline at (800) 995-5911 Monday-Friday, 9AM-6PM EST. 2. Cycle moonroof to open position. 3. Check for proper drain tube action by pouring approximately 1.8L (6 oz) of water into trough at each side. 4. If tubes appear to be draining properly, remove the interior A-pillar trim and sun visors. Refer to the appropriate Workshop Manual, Section 501-05. 5. Pull down the headliner slightly and inspect moonroof drain tubes for kinks and/or twists. The drain tubes must be free from any bends or obstruction of water flow. 6. Straighten or cut drain tubes to proper length to allow for free draining. Grommets Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 9497 Refer To Figure 8 1. Check for missing or improperly seated grommets in the following areas: ^ Antenna grommet on passenger side cowl ^ Park brake cable grommet on driver side cowl ^ Overall instrument panel grommets 2. Reseat any loose grommets or replace any missing grommets. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Handle-Outside, Front Door Removal 1. NOTE: The front door window glass must be completely raised. Remove the front door trim panel. 2. Position aside the front door watershield. 3. If equipped disconnect the electrical connector and release the pin-type retainers. 4. Disconnect the exterior front door handle actuating rod. 5. If equipped disconnect the lock cylinder actuating rod. 6. Remove the nuts and the exterior front door handle. Installation 1. NOTE: Make sure the door handle and lock cylinder rods are not preloading the latch. They should be clipped in a relaxed state with no slack. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip Front Door Panel: Technical Service Bulletins Interior Door Trim Panel - Replacement Tip Article No. 99-8-15 05/03/99 INTERIOR TRIM - DOOR TRIM PANEL REPLACEMENT - SERVICE TIP FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, MUSTANG 1996-1999 ESCORT, TAURUS 1998-1999 ESCORT ZX2 LINCOLN-MERCURY: 1993-1998 MARK VIII 1995-1997 COUGAR 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, TOWN CAR 1996-1999 SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1993-1996 BRONCO 1993-1997 F SUPER DUTY, F-250 HD, F-350 1993-1999 F-150, F-250 LD 1995-1997 AEROSTAR 1995-1999 ECONOLINE, EXPLORER, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE There has been an increase in the number of door trim panel replacements due to damage. This may be caused by a misconception of the type of fastener used to secure the door trim panel. ACTION Review the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior to removing the door trim panel. Use the Quick Reference Guide at the end of this article to determine the type of fastener used for the vehicle being worked on. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 9509 For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force applied during the door trim panel removal procedure. Refer to the Door Trim Panel Attachment Scheme Chart to identify vehicles with molded hook designs. WARNING REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE TRIM PANEL. Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop Manual, Section 01-05/501-05. OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 9510 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000,112000,190000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 9511 Front Door Panel: Service and Repair Removal 1. NOTE: Release the top portion first. Remove the sail panel. 2. Remove the window regulator switch plate. 3. Disconnect the electrical connectors. 4. Remove the upper door trim panel screw. 5. Remove the door trim panel screw at the window regulator switch plate opening. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 9512 6. Remove the door trim panel screw in the courtesy lamp housing. 1. Remove the courtesy lamp lens. 2. Remove the screw. 7. Remove the inside door handle trim cover. 8. Remove the inside door handle. - Remove the bolt. 9. CAUTION: To avoid damage to the front door trim panel, do not pull directly outward. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 9513 Lift upward and then outward to remove the front door trim panel. 10. Remove the courtesy lamp and socket. 11. Disconnect the power mirror electrical connector. Installation 1. Connect the power mirror electrical connector. 2. Install the courtesy lamp and socket. 3. Install the front door trim panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 9514 4. Install the inside door handle. - Install the bolt. 5. Install the inside door handle trim cover. 6. Install the door trim panel screw in the courtesy lamp housing. 1. Install the screw. 2. Install the courtesy lamp lens. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 9515 7. Install the door trim panel screw at the window regulator switch plate opening. 8. Install the upper door trim panel screw. 9. Connect the electrical connectors. 10. NOTE: If a new trim panel is required: Some new trim panels have a cut out opening for the window switchplate that is larger than that on the original trim panel. When installing a new trim panel, install the window switchplate in the following sequence to make sure that the switchplate is secured fully into the door trim panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 9516 Install the window regulator switchplate. - Insert the rear switchplate clip into the trim panel opening. - Install the forward and side clips into the trim panel opening. 11. NOTE: Install the lower portion first. Install the sail panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the front door radio speaker. 3. Remove the front door watershield. 4. Lower the window glass to access the two window glass to regulator nuts. 5. Remove the inside glass weatherstrip. 6. Remove the front door rear glass channel bolt and position the channel aside. 7. Remove the window glass to regulator nuts. 8. Remove the front door window glass. NOTE: Slide the glass through the outboard side of the door. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Page 9520 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Heavy Duty Riverter Special Tool(s) REMOVAL NOTE: The window regulator and motor are removed as an assembly. 1. Remove the front door trim panel. See: 2. Remove the front door radio speaker. 3. Remove the front door watershield. 4. Raise and support the front door window glass to the full up position. CAUTION: Support the window glass to avoid damage. 5. Disconnect the power window motor electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 9524 6. Remove the window glass to regulator nuts. 7. Remove the motor and window regulator assembly. 1 Drill out the rivets. 2 Remove the motor and window regulator assembly. 8. Remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. NOTE: Prior to motor removal, ensure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 9525 1. To install, reverse the removal procedure. - Use Heavy Duty Riveter to install the new rivets. - Cycle the door glass to ensure gear engagement. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 REMOVAL 1. Remove the rear door trim panel. 2. Remove the rear door watershield. 3. Remove the outside rear door handle. 1. Remove the nuts. 2. Disconnect the rear door latch to outside rear door handle rod. 3. Remove the outside rear door handle by pushing it out from the bottom surface of the handle. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the door handle and the rear door handle rod is in a relaxed position and that the rear door handle rod is all the way up before closing the clips. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip Rear Door Panel: Technical Service Bulletins Interior Door Trim Panel - Replacement Tip Article No. 99-8-15 05/03/99 INTERIOR TRIM - DOOR TRIM PANEL REPLACEMENT - SERVICE TIP FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, MUSTANG 1996-1999 ESCORT, TAURUS 1998-1999 ESCORT ZX2 LINCOLN-MERCURY: 1993-1998 MARK VIII 1995-1997 COUGAR 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, TOWN CAR 1996-1999 SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1993-1996 BRONCO 1993-1997 F SUPER DUTY, F-250 HD, F-350 1993-1999 F-150, F-250 LD 1995-1997 AEROSTAR 1995-1999 ECONOLINE, EXPLORER, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE There has been an increase in the number of door trim panel replacements due to damage. This may be caused by a misconception of the type of fastener used to secure the door trim panel. ACTION Review the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior to removing the door trim panel. Use the Quick Reference Guide at the end of this article to determine the type of fastener used for the vehicle being worked on. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 9535 For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force applied during the door trim panel removal procedure. Refer to the Door Trim Panel Attachment Scheme Chart to identify vehicles with molded hook designs. WARNING REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE TRIM PANEL. Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop Manual, Section 01-05/501-05. OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 9536 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000,112000,190000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Page 9537 Rear Door Panel: Service and Repair Removal 1. Remove the window regulator switchplate. 2. Disconnect the electrical connector. 3. Remove the rear door handle trim cover. 4. Remove the rear inside door handle. - Remove the door handle bolt. 5. Remove the rear door trim panel screws. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Page 9538 6. CAUTION: To avoid damage to the rear door trim panel, do not pull directly outward. Lift upward and then outward to remove the rear door trim panel. Installation 1. Install the rear door trim panel. 2. Install the rear door trim panel screws. 3. Install the rear inside door handle. - Install the door handle bolt. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Page 9539 4. Install the rear door handle trim cover. 5. Connect the electrical connector. 6. NOTE: If a new trim panel is required: Some new trim panels have a cut out opening for the window switchplate that is larger than that on the original trim panel. When installing a new trim panel, install the window switchplate in the following sequence to make sure that the switchplate is secured fully into the door trim panel. 7. Install the window regulator switchplate. - Insert the rear switchplate clip into the trim panel opening. - Install the forward and side clips into the trim panel opening. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL 1. Remove the rear door trim panel. 2. Remove the rear door radio speaker. 3. Remove the rear door watershield. 4. Remove the inside glass weatherstrip. 5. Remove the rear door glass channel lower bolt. 6. Remove the rear door fixed vent screw. 7. Lift the rear door rear glass and channel away from the door glass. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Page 9543 8. Remove the window glass to regulator nuts. 9. Remove the rear door glass. NOTE: Slide the glass through the outboard side of the door. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Window Regulator Nuts ....................................................................................................................... ............................................ 10-14 Nm (7.4-10 ft lb) Power Window Motor Bolts ........................................................................................................................................................... 5.6-9.1 Nm (50-81 in lb) Window Glass to Regulator Nuts ..................................................................................................................................................... 10-14 Nm (7.4-10 ft lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications > Page 9547 Rear Door Window Regulator: Service and Repair Heavy Duty Riverter Special Tool(s) REMOVAL NOTE: The window regulator and motor are removed as an assembly. 1. Remove the rear door trim panel. See: 2. Remove the rear door radio speaker. 3. Remove the rear door watershield. 4. Raise and support the rear door window glass to the full up position. CAUTION: Support the window glass to avoid damage. 5. Disconnect the power window motor electrical connector. 6. Remove the window glass to regulator nuts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications > Page 9548 7. Remove the motor and window regulator assembly. 1 Drill out the rivets. 2 Remove the motor and window regulator assembly. 8. Remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. NOTE: Prior to motor removal, ensure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy Duty Riveter to install the new rivets. - Cycle the door glass to ensure gear engagement. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair REMOVAL 1. Disconnect the heated backlite electrical connector. 2. Remove the liftgate trim panels. 3. Disconnect the liftgate window glass support. 1 Remove the E-clip. 2 Remove the pin. 3 Disconnect the support. NOTE: Have an assistant hold the liftgate window glass. 4. Remove the liftgate window glass. 1 Remove the four bolts (two each side). 2 Remove the liftgate window glass. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 9553 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9558 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9559 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9560 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9561 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9562 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement Technical Service Bulletin # 00S05 Date: 000501 Recall - Trailer Hitch Hardware Replacement 00S05 SAFETY RECALL All 1997-2000 Model Year Expedition and Navigator with Trailer Hitch Package - Hitch Attachment ^ Original - May, 2000 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Notification Letter ^ Supplement # 1 - May, 2000 Aftermarket Hitch Kits and Existing Dealer Stock Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9572 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9573 Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instruction on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Attachment II Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9574 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts wilt not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information shown. SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III AFFECTED VEHICLES: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9575 CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9576 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9577 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9578 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9579 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9580 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9581 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9582 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9583 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT (I )Immediately contact any affected owner whose name is not on the list Give the owner a copy of the Owner Letter and schedule a service date. This contact includes owners who have purchased aftermarket hitch kit # F75Z-17D826-AE. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9584 REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Supplement # 1 - Attachment II LABOR ALLOWANCES PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9585 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown above. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information above: SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. (I )REWORK OF EXISTING DEALER STOCK Call the Recall Hotline at 1-800-325-5621,to obtain instructions for reworking existing stock of Trailer Hitch Kits (part # F75Z-17D826-AE). NOTE: The Recall Hotline will provide new hardware and kit installation instructions.When you rework dealer stock, please make sure these revised instructions (with new torque specifications) are included in the kit. DEALER PRICE For latest prices, refer to: ^ DOESII ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Supplement # 1 - Attachment III HITCH ATTACHING FASTENER REPLACEMENT AFFECTED VEHICLES: CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9586 SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9587 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch. ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9588 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9589 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9590 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9591 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > NHTSA00V073000 > Mar > 00 > Recall 00V073000: Trailer Hitch Attaching Bolts Loose Trailer Hitch: Recalls Recall 00V073000: Trailer Hitch Attaching Bolts Loose Vehicle Description: Multi-purpose vehicles. The trailer hitch assembly to the frame attaching bolts could lose the clamp load. The trailer hitch could then separate from the vehicle. Dealers will replace the trailer hitch mounting bolts and nut plates. Owner notification began May 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1997 FORD TRUCK EXPEDITION 1997 LINCOLN TRUCK NAVIGATOR 1998 FORD TRUCK EXPEDITION 1998 LINCOLN TRUCK NAVIGATOR 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR 2000 FORD TRUCK EXPEDITION 2000 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement Technical Service Bulletin # 00S05 Date: 000501 Recall - Trailer Hitch Hardware Replacement 00S05 SAFETY RECALL All 1997-2000 Model Year Expedition and Navigator with Trailer Hitch Package - Hitch Attachment ^ Original - May, 2000 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Notification Letter ^ Supplement # 1 - May, 2000 Aftermarket Hitch Kits and Existing Dealer Stock Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9601 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9602 Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instruction on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Attachment II Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9603 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts wilt not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information shown. SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III AFFECTED VEHICLES: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9604 CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9605 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9606 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9607 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9608 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9609 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9610 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9611 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9612 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT (I )Immediately contact any affected owner whose name is not on the list Give the owner a copy of the Owner Letter and schedule a service date. This contact includes owners who have purchased aftermarket hitch kit # F75Z-17D826-AE. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9613 REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Supplement # 1 - Attachment II LABOR ALLOWANCES PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9614 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown above. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information above: SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. (I )REWORK OF EXISTING DEALER STOCK Call the Recall Hotline at 1-800-325-5621,to obtain instructions for reworking existing stock of Trailer Hitch Kits (part # F75Z-17D826-AE). NOTE: The Recall Hotline will provide new hardware and kit installation instructions.When you rework dealer stock, please make sure these revised instructions (with new torque specifications) are included in the kit. DEALER PRICE For latest prices, refer to: ^ DOESII ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Supplement # 1 - Attachment III HITCH ATTACHING FASTENER REPLACEMENT AFFECTED VEHICLES: CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9615 SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9616 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch. ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9617 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9618 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9619 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9620 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > NHTSA00V073000 > Mar > 00 > Recall 00V073000: Trailer Hitch Attaching Bolts Loose Trailer Hitch: All Technical Service Bulletins Recall 00V073000: Trailer Hitch Attaching Bolts Loose Vehicle Description: Multi-purpose vehicles. The trailer hitch assembly to the frame attaching bolts could lose the clamp load. The trailer hitch could then separate from the vehicle. Dealers will replace the trailer hitch mounting bolts and nut plates. Owner notification began May 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1997 FORD TRUCK EXPEDITION 1997 LINCOLN TRUCK NAVIGATOR 1998 FORD TRUCK EXPEDITION 1998 LINCOLN TRUCK NAVIGATOR 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR 2000 FORD TRUCK EXPEDITION 2000 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications Console: Specifications Console Finish Panel Front Screw ......................................................................................................................................... .................................. 2.1-2.9 Nm (18.7-25.8 in lb) Rear Screw .......................................................... .................................................................................................................. 2.1-2.9 Nm (18.7-25.8 in lb) Front Floor Console Front Bolts ........................................................................................................................................... ................................. 10.2-13.8 Nm (91-122 in lb) Rear Bolts ............................................................. ................................................................................................................ 10.2-13.8 Nm (91-122 in lb) Rear Floor Console Front Screws ....................................................................................................................................... .................................. 10.2-13.8 Nm (91-122 in lb) Rear Screws ........................................................ .................................................................................................................. 10.2-13.8 Nm (91-122 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Locations > Front Floor Console Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Locations > Front Floor Console > Page 9631 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Locations > Front Floor Console > Page 9632 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console: Service and Repair Front Floor REMOVAL 1. Disconnect the battery ground cable. 2. Remove the console finish panel mat. 3. Remove the console finish panel front screw. 4. Remove the console finish panel rear screw. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor > Page 9635 5. Remove the console finish panel. 6. Remove the front floor console front bolts. 7. Disconnect the front floor console electrical connector. 8. Remove the two front floor console rear bolt covers. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor > Page 9636 9. Remove the two front floor console rear bolts. 10. Remove the floor console. ^ Lift the front of the floor console and slide rearward to disengage the floor brackets. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor > Page 9637 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor > Page 9638 Console: Service and Repair Rear REMOVAL 1. Tilt the rear seats forward. 2. Remove the cupholder. NOTE: Pull upward on the center of the cupholder to release the pushpin fasteners. 3. Remove the rear floor console front screws. 4. Remove the two rear floor console rear screws. 5. Remove the rear floor console. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor > Page 9639 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect the battery ground cable. WARNING: THE BACKUP POWER SUPPLY ENERGY MUST BE DEPLETED BEFORE ANY AIR BAG COMPONENT REPAIR IS PERFORMED. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the driver side air bag module from the vehicle. WARNING: PLACE THE AIR BAG MODULE ON A BENCH WITH THE TRIM COVER FACING UP TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 4. Connect the air bag simulator to the vehicle harness at the top of the steering column. 5. Remove the passenger side air bag module from the vehicle. WARNING: PLACE THE AIR BAG MODULE ON A BENCH WITH THE DEPLOYMENT DOOR FACING UP TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 6. Connect the air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Reactivation Procedure 1. Disconnect the battery ground cable. WARNING: THE AIR BAG SIMULATORS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. In stall the driver side air bag module. 5. Remove the air bag simulator from the vehicle harness connector at the passenger side air bag module. 6. Install the passenger side air bag module. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 8. Prove out the system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 9645 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Are both air bag sensors connected and mounted to the vehicle? [ ] 2. Is the three-way connector at the base of the steering column connected? [ ] 3. Are the air bag modules or air bag simulators connected? [ ] 4. Is the air bag diagnostic monitor connected? [ ] 5. Is the vehicle battery connected? [ ] Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Locations > Page 9649 Glove Compartment: Service and Repair Glove Box Spring Tool Special Tool(s) REMOVAL 1. Open the glove compartment. 2. Lower the glove compartment. 1 Move the glove compartment stops to align with the opening. 2 Lower the glove compartment. 3. Install Glove Box Spring Tool Set. 1 Hold the glove compartment open. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Locations > Page 9650 2 Install Glove Box Spring Tool Set. 4. Remove the glove compartment. 1 Remove the bolts. 2 Remove the glove compartment. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel Trim Panel: Service and Repair Liftgate Trim Panel REMOVAL 1. Remove the upper liftgate trim panel. 2. Remove the liftgate assist strap. 1 Remove the screws. 2 Remove the liftgate assist strap. 3. Remove the lower lift gate trim panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel > Page 9655 Trim Panel: Service and Repair Quarter Trim Panel Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL 1. Remove the liftgate door opening weather seal. 2. Remove the liftgate scuff plate. 3. If equipped, remove the third row seat. 4. Remove the rear header garnish trim panel. 5. Remove the rear door scuff plates. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel > Page 9656 6. Fold down the second row seat. 7. Remove the cross car scuff plate. 8. Remove the second row safety belt guide nut. 1 Lift the cover. 2 Remove the nut. 9. Remove the second row safety belt lower nut. 10. Remove the C-pillar trim panel. ^ Remove the rear door opening weather seal. ^ Remove the C-pillar trim panel. NOTE: Remove the upper attachments followed by the lower attachment and the lower rear hook. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel > Page 9657 11. If equipped, remove the third row safety belt guide. 1 Lift the cover. 2 Use Safety Belt Bolt Bit to remove the safety belt guide bolt. 3 Remove the third row safety belt guide. 12. Remove the D-pillar trim panel. ^ Remove the liftgate door opening weather seal. NOTE: Remove the lower hook attached to the quarter trim panel, followed by the top attachment, and then the lower rear attachment. 13. Remove the quarter trim panel. 1 Remove the screws and pin-type retainer. 2 Remove the quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel > Page 9658 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Door Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9665 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9666 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9667 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9668 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9669 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9675 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9676 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications RAP Module Nuts ................................................................................................................................ ......................................................... 7 Nm (62 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 9680 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 9681 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 9682 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Disconnect the C257 and C256 Remote Anti-theft Personality (RAP) module electrical connectors. 3. Remove the nuts and the RAP module. NOTE: On Expedition and later build Navigators, the antenna is internal to the module and must be replaced as an assembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 9683 strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Description and Operation Keyless Entry Transmitter: Description and Operation NOTE: The remote entry features will not function when the ignition switch is in the RUN or ACC position. The keyless entry remote transmitter initiates the following electronic door lock and memory (Navigator only) system functions: ^ Unlocks the driver door. ^ Unlocks the driver door and moves the memory seat and mirrors into their corresponding memory positions. (Only available with the remote memory feature). ^ Unlocks all doors. ^ Locks all doors. ^ Enables the panic alarm. ^ Turns on the interior lamps when unlocking and off when locking. ^ Chirps the horn once when the LOCK button on the keyless entry remote transmitter is pressed twice and all doors are closed. ^ Chirps the horn twice when the LOCK button on the keyless entry remote transmitter is pressed twice and a door is left open. ^ Allows up to four keyless entry remote transmitters to be programmed. NOTE: If more than five seconds have elapsed since the first press of the UNLOCK button, pressing the UNLOCK button again will only unlock the driver door a second time. To unlock the driver door press the UNLOCK button on the keyless entry remote transmitter. To unlock all doors press the UNLOCK button on the keyless entry remote transmitter a second time, within five seconds of the first unlock. To lock all doors press the LOCK button on the keyless entry remote transmitter once. To confirm that the doors have been locked press the LOCK button again, within five seconds of the first press. The horn will chirp once if the doors Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Description and Operation > Page 9687 have locked and all doors are closed. The horn will chirp twice if a door is still open. To activate the panic alarm press the red PANIC button on the keyless entry remote transmitter. The horn will sound and the headlamps and exterior lamps will flash for a maximum of two minutes and 45 seconds. To deactivate the panic alarm press the red PANIC button again on the keyless entry remote transmitter or turn the ignition switch to RUN/ACC. Enable/Disable Mode The enable/disable mode allows the autolock and memory seat/mirror (Navigator only) features to be turned off and on. There are PIDS in RAP (Autolock and MEM-SEAT) which reflect if the feature is ON or OFF. The RAP Active Command Module Configuration can be used to turn "Autolock" on/off and turn "Move MEM-SEAT w/Key fob" on/off or the enable/disable mode is entered when the following series of steps is performed: 1. Close all of the doors. 2. Confirm that the ignition switch is in the OFF position. NOTE: Steps 3 through 7 must be performed within 30 seconds. 3. Turn the ignition switch from OFF to RUN. 4. Press the power door lock UNLOCK button three times. 5. Turn the ignition switch from RUN to OFF. 6. Press the power door lock UNLOCK button three times. 7. Turn the ignition switch from OFF to RUN. 8. Verify that the RAP module chirps the horn. This indicates that the RAP module is now in the enable/disable mode and ready to accept program changes. 9. To change Autolock press the power door lock UNLOCK button one time to command the RAP module to toggle the autolock feature ON or OFF. 10. To change if the memory seat/mirrors will move when the keyfob unlock button is pressed, press the power door lock unlock button two times. 11. Press the power door lock LOCK button once to enter the command. 12. Verify that the vehicle horn chirps one time (Autolock feature) or two short chirps (memory seat recall feature) to signal the RAP module confirmation of the command. There should only be one chirp (Autolock feature) or two short chirps (memory seat recall feature) indicating that the feature has been disabled. If one chirp (for Autolock) or two chirps (for Memory Seat) is heard, followed by a longer honk, the feature has just been enabled. Return to step 9. 13. Turn the ignition switch to the OFF position to exit the enable/disable mode. 14. Verify that the RAP module chirps the horn once to indicate that a feature has been changed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Description and Operation > Page 9688 Keyless Entry Transmitter: Service and Repair TRANSMITTER PROGRAMMING NOTE: ^ The keyless entry remote transmitters are reprogrammable and must be set at the same time. ^ To program (or reprogram) the keyless entry remote transmitters into the RAP module, perform the following steps: 1. Turn the ignition switch from OFF to RUN eight times within ten seconds, ending in RUN. If the RAP module has successfully entered the program mode, it will lock and then unlock all doors. 2. Press any button on the keyless entry remote transmitter, and the doors will lock and then unlock to confirm that each keyless entry remote transmitter has been programmed. 3. If the door locks do not respond for any keyless entry remote transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Diagnosis and Testing. 4. Turn the ignition switch to the OFF position, or wait up to five minutesafter step 2, to exit the program mode. If a keyless entry remote transmitter has been programmed (or reprogrammed), the RAP module will lock and unlock all doors one last time to confirm. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay Power Door Lock Relay: Locations All Lock Relay Body View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9694 Lock Relays The All Lock Relay is located in lock relays. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9695 Power Door Lock Relay: Locations All Unlock Relay Body View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9696 Lock Relays The All Un-Lock Relay is located in lock relays. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9697 Power Door Lock Relay: Locations Driver's Door Unlock Relay Body View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9698 Lock Relays The Driver's Unlock Relay is located in the lock relays. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9699 Power Door Lock Relay: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Left Door Left Power Door Lock Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Left Door > Page 9704 Right Power Door Lock Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9709 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9710 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9711 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9712 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9713 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions Heated Element: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9719 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9720 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9721 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9722 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9723 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9724 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9725 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9726 Heated Element: Connector Views Left Power/Heated/Signal Mirror Right Power/Heated/Signal Mirror Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9727 Rear Window Defrost/Mirror Defrost Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation > Memory Power Driver Seat Operation Seat Memory Switch: Description and Operation Memory Power Driver Seat Operation The memory driver seat feature allows the driver to program a personalized seat position that can be recalled using the memory switches or remote entry key fob. There are three memory settings possible. The outside rear view mirror positions are also stored and recalled with the power driver seat positions. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 9733 Seat Memory Switch: Description and Operation Programming Seat Positions A power driver seat position can be stored at any time. The driver must move the seat to the desired position using the driver seat switch assembly. The driver must then depress the memory SET switch which activates the memory SET switch Light Emitting Diode (LED). Within five seconds (before the LED goes out), the driver must select a memory position. Memory 1 is selected by depressing memory switch 1. Memory 2 is selected by depressing memory switch 2. Memory 3 is selected by depressing both memory switch 1 and memory switch 2 simultaneously. If no memory switch input is received within the five second time limit, the operation is aborted and the memory SET switch LED is turned off. If one of the following inputs is received during the five secondprogramming limit, the operation is aborted and the memory SET switch LED is turned off: - Power driver seat switch. - Power outside rear view mirror switch. - Memory SET switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 9734 Seat Memory Switch: Description and Operation Recalling A Stored Seat Position NOTE: A memory recall can be initiated only if the vehicle is in PARK or NEUTRAL gear and the ignition switch is not in START. A memory recall in progress will not be affected by moving the ignition switch to START or by moving the gearshift lever out of PARK or NEUTRAL. Once the driver has stored the desired driver seat position, the driver can recall the setting by depressing the corresponding memory switch or by using a programmed remote entry transmitter. ^ The driver can recall the desired driver seat position by depressing one or both of the memory recall switches. Depressing memory switch 1 will initiate a recall of the power driver seat position stored in memory 1. Depressing memory switch 2 will initiate a recall of the power driver seat position stored in memory 2. Depressing memory switch 1 and memory switch 2 simultaneously will initiate a recall of the power driver seat position stored in memory 3. ^ A remote transmitter can be used to recall previously set memory positions. Transmitters are manufactured with an assigned personality number (1, 2, or 3) and are so designated on the back of the transmitter. The transmitter assigned with personality 1 is capable of recalling memory position 1 only. Similarly, the personality 2 and 3 transmitters can recall only memory positions 2 and 3 respectively. ^ Memory recall occurs when the UNLOCK switch is depressed on the transmitter. The second depression of the UNLOCK switch, which unlocks passenger doors, does not initiate a memory recall. ^ A memory recall in progress does not prohibit the initiation of another memory recall; the most recently requested memory recall will be executed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9747 ACTION To remove these particles/contaminates, use ONLY the following 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9748 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9749 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 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. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. 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 identitying 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9750 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 with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ 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 will be visible and may be felt. Decontamination Procedure Use Ford 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 Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./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 a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9751 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9757 ACTION To remove these particles/contaminates, use ONLY the following 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9758 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9759 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 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. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. 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 identitying 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9760 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 with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ 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 will be visible and may be felt. Decontamination Procedure Use Ford 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 Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./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 a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9761 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs Paint: All Technical Service Bulletins Paint - Materials For After Warranty/Warranty Repairs Article No. 98-18-2 09/14/98 PAINT - EXTERIOR - WORLDWIDE RECOMMENDED PAINT MATERIALS FOR WARRANTY AND AFTER WARRANTY REPAIRS FORD: 1997 ASPIRE, PROBE, THUNDERBIRD 1997-98 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1997 COUGAR 1997-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1997 AEROSTAR 1997-98 ECONOLINE, EXPEDITION, EXPLORER, F SUPER DUTY, F-150-350 SERIES, F-47, MOUNTAINEER, RANGER, VILLAGER, WINDSTAR 1998 NAVIGATOR MEDIUM/HEAVY TRUCK: 1997-98 AEROMAX, CARGO SERIES, F & B SERIES, L SERIES, LOUISVILLE This TSB article is being republished in its entirety to add additional paint information. ISSUE Ford Motor Company's goal is to eliminate paint related repeat repairs and increase customer satisfaction. To meet this goal, Ford has tested refinish paint materials that are used for warranty. Tests conducted were designed around OEM Refinish Material Reliability and Durability Standards. ACTION Ford Customer Service Division (FCSD) has released a paint material specification (WSS-M2P100-D) to the major worldwide paint supply companies for testing refinish paint systems. These paint systems are used for refinishing service parts as well as repair steel and plastic OEM finishes. SYSTEMS TESTED Ford Motor Company has completed testing of refinish paint materials that are compliant to U.S. "National Rule," "Canadian Rule" and European VOC (Volatile Organic Compounds) regulations. NOTE TESTING OF CALIFORNIA VOC COMPLIANT SYSTEMS WILL BEGIN 9/98 DUE TO A RECENT MORATORIUM REQUIRING NEW EMISSION COMPLIANT PRODUCTS. SELECTION AND PREPARATION Each paint manufacturer was asked to submit worldwide "in-use" paint systems for testing. The paint materials used for testing were obtained by Ford from local paint jobbers and distributors and/or shipped in from Europe. Employees of each paint company prepared and sprayed the test panels. All testing was completed at the Ford Central Laboratory facility. SUBSTRATES AND TESTS The paint materials approved from these specifications were tested over the following substrates: cold rolled steel, E-coated steel, bare galvanized steel, sanded OEM finish, and TPO plastic. A select group of tests including salt spray, initial adhesion, chipping, fuel resistance, and thermal shock were used for screening. As the companies passed the screening tests, they were required to complete the balance of the tests listed in the specifications. Each panel was tested and reviewed per OEM testing methods. PAINT PRODUCT CHANGES If a paint company decides to introduce a new product into a tested system (i.e., new primer, same clearcoat), the entire system will require retesting. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9766 Systems will only be tested once a year. Cost of testing will be the responsibility of the paint suppliers. APPROVED SUPPLIERS AND MATERIALS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9767 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9768 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9769 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9770 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9771 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9772 The Charts following this article (Figures 1-7) indicate paint suppliers and materials. Dealers should begin to use the recommended paint materials as soon as practical. Dealers without a body shop should provide a copy of this bulletin to the independent body shop performing their warranty repairs. The products listed in this bulletin may be made mandatory sometime in the future. As a result, dealers that have jobber/paint company contractual agreements should only contract with recommended suppliers (when existing contracts expire) CONCLUSIONS Testing of refinish materials will raise standards for these materials. These improved standards will result in improved customer satisfaction. OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9773 SUPERSEDES: 98-9-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-4-4 > Mar > 98 > Paint - Anti Chip Stone Abrasion Undercoat Service Tip Paint: All Technical Service Bulletins Paint - Anti Chip Stone Abrasion Undercoat Service Tip Article No. 98-4-4 03/02/98 PAINT - ANTI-CHIP STONE ABRASION UNDERCOAT - SERVICE TIP FORD: 1998 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1998 CONTINENTAL, GRAND MARQUIS, MARK VIII, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1997 AEROSTAR 1998 ECONOLINE, EXPEDITION, EXPLORER, F SUPER DUTY, F-150, F-250 LD, MOUNTAINEER, NAVIGATOR, RANGER, VILLAGER, WINDSTAR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1998 F & B SERIES ISSUE: There may be some difficulty in matching the texture of the OEM Anti-chip Stone Abrasion material to repair materials when servicing. ACTION: Remove the affected material, apply repair material, and paint. Refer to the following Service Procedure for details. WARNING: WEAR RESPIRATORY PROTECTION. WEAR PROTECTIVE CLOTHING WHEN EVER POTENTIALLY HAZARDOUS MATERIALS OR CONDITIONS EXIST IN THE SHOP. Areas that have been treated with Anti-chip Stone Abrasion materials show more textured appearance than the other painted areas of the body. Areas of application are the rocker panels and areas fore and aft of the rear wheels. Ford uses two types of stone abrasion materials, urethane (orange peel appearance) and PVC (smooth appearance). When repairs are needed, the coating must be removed from the entire side of the vehicle. No spot repairs can be performed on this material. NOTE: THIS PROCEDURE HIGHLIGHTS BASF STONE ABRASION MATERIAL; HOWEVER, OTHER MATERIALS LISTED BELOW MAY BE USED. ANY FORD APPROVED PAINT SYSTEM CAN BE USED. SERVICE PROCEDURE 1. Thoroughly wash the vehicle with soap and warm water. Power wash any heavy deposits of grime. 2. Remove all traces of grease, wax, and oil with Glasurit 541-5 Silicone and Tar Remover. 3. Sand previously painted areas with 240/P320 grit sand paper. 4. Wipe the area clean with a pre-paint cleaner, then wipe with tack cloth. NOTE: ALL BODY FILLER MUST BE PRIMED BEFORE STONE ABRASION MATERIAL IS APPLIED. FOLLOW RECOMMENDED FLASH TIME FOR PRIMER MATERIALS. 5. Mix and spray one (1) full wet coat of epoxy primer. NOTE: THE AMOUNT OF TEXTURE IS HIGHLY DEPENDENT ON APPLICATION TECHNIQUE AND SPRAY EQUIPMENT. USE A GRAVITY FEED GUN WITH 2.2 mm TIP SIZE. FOLLOW RECOMMENDED FLASH TIME. ALLOW MATERIAL TO DRY BEFORE TOPCOATING. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-4-4 > Mar > 98 > Paint - Anti Chip Stone Abrasion Undercoat Service Tip > Page 9778 BAKE TIME 30 MINUTES AT 60°C (140°F) OR INFRA-RED LIGHT 7-20 MINUTES. AIR DRY 2 HOURS. REMOVE ANY OVERSPRAY WITHIN 15 MINUTES WITH A DAMP SPONGE (WATER) OR WIPE WITH 352-91 REDUCER. CLEAN SPRAY EQUIPMENT IMMEDIATELY WITH WATER. 6. Spray one (1) or two (2) full wet coat(s) of ready-to-spray Anti-chip Stone Abrasion material. 7. Mix and spray Ford approved basecoat material to hiding. Follow recommended flash time. 8. Mix and spray two (2) full wet coats of Ford approved clearcoat material. Follow recommended flash time. Anti-chip Stone Abrasion Materials: ^ Glasurit 1109-1240-6 Stone Chip Protector ^ Gravi-tex ^ Dominion Shure Seal Gravel Gard III ^ Dominion Shure Seal Rocker Gard 8949 ^ 3M Rocker Schutz ^ 3M Rocker Gard II ^ PPG RoadGard DX54 ^ Spies Hecker Stone Chip Protector 7100-7104 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-3-3 > Feb > 98 > Paint - Surface Defect Removal Without Repainting Technical Service Bulletin # 98-3-3 Date: 980216 Paint - Surface Defect Removal Without Repainting Article No. 98-3-3 02/16/98 PAINT - SURFACE DEFECT REMOVAL WITHOUT REPAINTING - SERVICE TIP FORD: 1997 ASPIRE, PROBE, THUNDERBIRD 1997-98 CONTOUR 1998 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1997 COUGAR 1997-98 MYSTIQUE 1998 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1997 AEROSTAR 1997-98 EXPEDITION, EXPLORER, F-150, F-250 LD, F-250 LD, MOUNTAINEER, RANGER, VILLAGER, WINDSTAR 1998 ECONOLINE, NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1997 AEROMAX, CARGO SERIES, F & B SERIES, L SERIES, LOUISVILLE ISSUE: Exterior paint surface maintenance or damage repair where the basecoat does not show through should be restored without repainting. The restoration of gloss and luster may be enhanced with new techniques and three new Ford approved materials. ACTION: The following procedure is applicable to repair surface conditions such as dirt particles, "orange peel," runs, sags, industrial fallout stains, swirl marks, and scratches. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Preparation The affected surface must be clean and dry to be repaired. Mask off adjacent panels, mouldings, stripe, and character lines as required. CAUTION: EYE PROTECTION SHOULD BE WORN. JEWELRY, WATCHES, AND BELT BUCKLES MUST BE REMOVED OR COVERED TO PREVENT ACCIDENTAL DAMAGE TO PAINT FINISH. NOTE: CHECK PAINT FILM THICKNESS BEFORE AND AFTER PERFORMANCE OF REPAIRS. MAXIMUM PAINT FILM REMOVAL IS 0.3 OF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-3-3 > Feb > 98 > Paint - Surface Defect Removal Without Repainting > Page 9783 A MIL. NOTE: PERFORM A TRIAL REPAIR ON A SMALL AREA. FIRST, TRY A POLISH; IF THIS IS NOT SUCCESSFUL, TRY BUFFING WITH FORD MEDIUM DUTY BODY SHOP PAINT CLEANER (F6AZ-19530-BA) OR FORD HEAVY DUTY BODY SHOP PAINT CLEANER (F6AZ-19530-CA) AND, FINALLY, USE WET SANDING TO REMOVE THE CONDITION. USE THE MOST EFFECTIVE TECHNIQUE ON THE REMAINING AREAS. AN OUTLINE OF THE COMPLETE PROCEDURE AND REQUIRED MATERIALS FOLLOWS. Service Notes 1. Remove sanding marks with Ford Medium or Heavy Duty Body Shop Paint Cleaner. 2. Swirl marks, evident after buffing, may be removed by polishing with Ford Light Duty Body Shop Polish (F6AZ-19530-BA). 3. Remove light scratches and small dirt particles with a power buffer and Ford Medium Duty Body Shop Pain Cleaner followed by polishing with Ford Light Duty Body Shop Polish. 4. Remove deep scratches and heavy dirt particles or "orange peel" by wet sanding. Removing Scratches/Swirl Marks/Restore Dull Finish The Black and Decker Buffmaster(R) 5950 is the tool of choice. Variable speed buffers are available in a variety of buffing speeds. The recommended speed range is (1200-1750 rpm). 1. Apply a small amount of Ford Light Duty Body Shop Polish to the pad. ^ Always keep the face of the buffing pad completely flat to the surface, reducing the risk of buffer swirl marks. Watch your pad, especially on angled surfaces, to be certain that it stays flat ^ When "buffing out" oxidation or other paint defects with a cleaning material, use a liberal amount of material, slower buffing motion and added downward pressure to increase cutting action 2. When polishing, keep the pad flat against the surface. Do not bear down. The weight of the buffer is suffi6ient. CAUTION: DO NOT MIX PRODUCTS. USE A SEPARATE, DEDICATED BUFFING PAD FOR EACH PRODUCT TO ACHIEVE DESIRED RESULTS. Med. Scratches, Small Dirt Particles, Grind & Sanding Marks 1. Apply Ford Medium Duty Body Shop Paint Cleaner to the panel with a clean compound pad on the wheel. 2. Spread the product evenly and continue buffing until the condition is removed. 3. Keep the wheel flat to the surface and use light to moderate pressure and long strokes. 4. Periodically check the finish and add product as required. 5. When buffing is complete, polish the panel as described previously. Untreated wool cutting pads are the most effective cutting pads to use with Ford Heavy Duty Body Shop Paint Cleaner for removing paint defects and heavy oxidation. Following the use of a wool cutting pad, it may be necessary to polish the finish with a foam pad to remove the deep swirl marks. NOTE: ALWAYS KEEP THE PAD MOVING AND LIMIT YOUR STROKES OVER THE BLEMISH TO PREVENT EXCESSIVE HEAT BUILDUP AND POSSIBLE BURN-THROUGH. STOP IMMEDIATELY IF THE SURFACE BECOMES TOO HOT TO LAY THE PALM OF YOUR HAND ON IT. KEEP SURFACE TEMPERATURE BELOW 38°C (100°F). NOTE: HEAT BUILDUP: WHEN BUFFING CREATES EXCESSIVE HEAT, HAZING MAY APPEAR ACROSS THE SURFACE BEING BUFFED AND THE PRODUCT MAY DRY LIKE A FILM AND REFUSE TO BUFF OUT. TO REMEDY, WIPE THE AREA DOWN WITH COOL WATER, DRY THE SURFACE AND RESUME BUFFING, AT A LOWER RPM IF POSSIBLE. NOTE: STATIC: STATIC ELECTRICITY MAY BE PRESENT ON A PAINTED FIBERGLASS/PLASTIC SURFACE BEING BUFFED. THE MATERIAL MAY DRY LIKE A FILM OR TURN "GUMMY" AND BEGIN TO BALL UP. TO REMEDY, ATTACH A GROUNDING CLAMP TO THE SURFACE BEING BUFFED TO ELIMINATE THE STATIC CHARGE. Run and Sag Removal This procedure consists of shaving the run(s) or sag(s) flush with a commercial single edge razor blade, shaving file or sanding. NOTE: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-3-3 > Feb > 98 > Paint - Surface Defect Removal Without Repainting > Page 9784 IF IT IS NECESSARY TO SHAVE RUNS AND SAGS WITH A RAZOR BLADE, FIRST DULL THE CORNERS WITH SANDPAPER TO AVOID SCRATCHING THE ADJACENT AREA FINISH. 1. Lightly scrape the defect until the defect is level with the surface. 2. Wet sand or compound the surface to remove any small scratches. 3. Polish to complete the repair. Wet Sanding For Defect Removal ^ Typical paint defects that are repaired with this system include: dirt in paint, solvent "pop," cratering, "orange peel," drips, scratches, water spots, and acid rain ^ Always use the least abrasive (highest grit) sanding products possible to do this job The following wet sanding procedure utilizes light grit sandpaper or sanding blocks for removal of surface damage. These materials cut quickly, leaving a uniform finish requiring a minimum of buffing to restore gloss. 1. Mist or apply water on the area to be sanded. Continue to flush water on the surface during sanding for maximum lubrication. 2. Use sanding blocks or paper. Keep abrasion to the immediate area of the defect. Keep blocks in water when not in use. 3. If the cutting is too slow, switch to a lower grade block or paper and resume sanding. When 90% of the defect is removed, switch to a 2000 grade sand paper or sanding block to finish smoothing and prepare the surface for buffing. 4. Sanding blocks can be shaped to work on any angle. When the block is wet, rub it against a dry sanding block for shaping. 5. When using sanding papers, wrap the paper tightly around a backing pad. This pad evenly distributes pressure over the entire surface of the sanding paper. This creates a uniform sanding pattern. 6. Plan your strokes to limit the abrasion to the smallest area possible. 7. Always finish sanding with 2000 Grit Sanding Paper. 2000 grit paper will reduce the need for heavy compound, however, the area should be finished by using a cleaner that will remove the sanding scratches left by these papers. NOTE: IF MULTIPLE GRIT PAPERS ARE USED, IT IS A GOOD IDEA TO CHANGE THE DIRECTION OF SANDING STROKE TO ALLOW YOU TO SEE THAT THE PREVIOUS GRIT SCRATCH IS REMOVED. 8. Buff out sanding marks by applying Ford Medium Duty Body Shop Paint Cleaner with a "Foam" Cutting Pad (W7000). Follow with Ford Light Duty Body Shop Polish for a swirl-free gloss. General Techniques and Hints ^ "Foam" buffing pads yield maximum gloss and depth of color on all types of paint finishes without creating buffer swirl marks ^ Always apply product directly to pad, not to oxidized paint surface. Dry paint absorbs material into pores upon contact ^ Avoid short rapid strokes. Move the buffer slowly across the surface using long straight motions and overlap by 50% the buffing pattern left by the previous pass. This insures uniform coverage and allows both material and buffer to perform at maximum efficiency ^ Avoid buffing directly on raised character lines. The reduced paint film on these surfaces increases the risk of paint burn-through. It is best to buff up to them from each side ^ If a paint blemish remains after buffing, reapply a small amount of material over the blemish~ Confine your buffing strokes to the immediate area of the blemish while applying additional downward pressure and keeping the pad flat Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs Paint: All Technical Service Bulletins Paint - Materials For After Warranty/Warranty Repairs Article No. 98-18-2 09/14/98 PAINT - EXTERIOR - WORLDWIDE RECOMMENDED PAINT MATERIALS FOR WARRANTY AND AFTER WARRANTY REPAIRS FORD: 1997 ASPIRE, PROBE, THUNDERBIRD 1997-98 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1997 COUGAR 1997-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1997 AEROSTAR 1997-98 ECONOLINE, EXPEDITION, EXPLORER, F SUPER DUTY, F-150-350 SERIES, F-47, MOUNTAINEER, RANGER, VILLAGER, WINDSTAR 1998 NAVIGATOR MEDIUM/HEAVY TRUCK: 1997-98 AEROMAX, CARGO SERIES, F & B SERIES, L SERIES, LOUISVILLE This TSB article is being republished in its entirety to add additional paint information. ISSUE Ford Motor Company's goal is to eliminate paint related repeat repairs and increase customer satisfaction. To meet this goal, Ford has tested refinish paint materials that are used for warranty. Tests conducted were designed around OEM Refinish Material Reliability and Durability Standards. ACTION Ford Customer Service Division (FCSD) has released a paint material specification (WSS-M2P100-D) to the major worldwide paint supply companies for testing refinish paint systems. These paint systems are used for refinishing service parts as well as repair steel and plastic OEM finishes. SYSTEMS TESTED Ford Motor Company has completed testing of refinish paint materials that are compliant to U.S. "National Rule," "Canadian Rule" and European VOC (Volatile Organic Compounds) regulations. NOTE TESTING OF CALIFORNIA VOC COMPLIANT SYSTEMS WILL BEGIN 9/98 DUE TO A RECENT MORATORIUM REQUIRING NEW EMISSION COMPLIANT PRODUCTS. SELECTION AND PREPARATION Each paint manufacturer was asked to submit worldwide "in-use" paint systems for testing. The paint materials used for testing were obtained by Ford from local paint jobbers and distributors and/or shipped in from Europe. Employees of each paint company prepared and sprayed the test panels. All testing was completed at the Ford Central Laboratory facility. SUBSTRATES AND TESTS The paint materials approved from these specifications were tested over the following substrates: cold rolled steel, E-coated steel, bare galvanized steel, sanded OEM finish, and TPO plastic. A select group of tests including salt spray, initial adhesion, chipping, fuel resistance, and thermal shock were used for screening. As the companies passed the screening tests, they were required to complete the balance of the tests listed in the specifications. Each panel was tested and reviewed per OEM testing methods. PAINT PRODUCT CHANGES If a paint company decides to introduce a new product into a tested system (i.e., new primer, same clearcoat), the entire system will require retesting. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9790 Systems will only be tested once a year. Cost of testing will be the responsibility of the paint suppliers. APPROVED SUPPLIERS AND MATERIALS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9791 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9792 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9793 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9794 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9795 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9796 The Charts following this article (Figures 1-7) indicate paint suppliers and materials. Dealers should begin to use the recommended paint materials as soon as practical. Dealers without a body shop should provide a copy of this bulletin to the independent body shop performing their warranty repairs. The products listed in this bulletin may be made mandatory sometime in the future. As a result, dealers that have jobber/paint company contractual agreements should only contract with recommended suppliers (when existing contracts expire) CONCLUSIONS Testing of refinish materials will raise standards for these materials. These improved standards will result in improved customer satisfaction. OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9797 SUPERSEDES: 98-9-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-4-4 > Mar > 98 > Paint - Anti Chip Stone Abrasion Undercoat Service Tip Paint: All Technical Service Bulletins Paint - Anti Chip Stone Abrasion Undercoat Service Tip Article No. 98-4-4 03/02/98 PAINT - ANTI-CHIP STONE ABRASION UNDERCOAT - SERVICE TIP FORD: 1998 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1998 CONTINENTAL, GRAND MARQUIS, MARK VIII, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1997 AEROSTAR 1998 ECONOLINE, EXPEDITION, EXPLORER, F SUPER DUTY, F-150, F-250 LD, MOUNTAINEER, NAVIGATOR, RANGER, VILLAGER, WINDSTAR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1998 F & B SERIES ISSUE: There may be some difficulty in matching the texture of the OEM Anti-chip Stone Abrasion material to repair materials when servicing. ACTION: Remove the affected material, apply repair material, and paint. Refer to the following Service Procedure for details. WARNING: WEAR RESPIRATORY PROTECTION. WEAR PROTECTIVE CLOTHING WHEN EVER POTENTIALLY HAZARDOUS MATERIALS OR CONDITIONS EXIST IN THE SHOP. Areas that have been treated with Anti-chip Stone Abrasion materials show more textured appearance than the other painted areas of the body. Areas of application are the rocker panels and areas fore and aft of the rear wheels. Ford uses two types of stone abrasion materials, urethane (orange peel appearance) and PVC (smooth appearance). When repairs are needed, the coating must be removed from the entire side of the vehicle. No spot repairs can be performed on this material. NOTE: THIS PROCEDURE HIGHLIGHTS BASF STONE ABRASION MATERIAL; HOWEVER, OTHER MATERIALS LISTED BELOW MAY BE USED. ANY FORD APPROVED PAINT SYSTEM CAN BE USED. SERVICE PROCEDURE 1. Thoroughly wash the vehicle with soap and warm water. Power wash any heavy deposits of grime. 2. Remove all traces of grease, wax, and oil with Glasurit 541-5 Silicone and Tar Remover. 3. Sand previously painted areas with 240/P320 grit sand paper. 4. Wipe the area clean with a pre-paint cleaner, then wipe with tack cloth. NOTE: ALL BODY FILLER MUST BE PRIMED BEFORE STONE ABRASION MATERIAL IS APPLIED. FOLLOW RECOMMENDED FLASH TIME FOR PRIMER MATERIALS. 5. Mix and spray one (1) full wet coat of epoxy primer. NOTE: THE AMOUNT OF TEXTURE IS HIGHLY DEPENDENT ON APPLICATION TECHNIQUE AND SPRAY EQUIPMENT. USE A GRAVITY FEED GUN WITH 2.2 mm TIP SIZE. FOLLOW RECOMMENDED FLASH TIME. ALLOW MATERIAL TO DRY BEFORE TOPCOATING. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-4-4 > Mar > 98 > Paint - Anti Chip Stone Abrasion Undercoat Service Tip > Page 9802 BAKE TIME 30 MINUTES AT 60°C (140°F) OR INFRA-RED LIGHT 7-20 MINUTES. AIR DRY 2 HOURS. REMOVE ANY OVERSPRAY WITHIN 15 MINUTES WITH A DAMP SPONGE (WATER) OR WIPE WITH 352-91 REDUCER. CLEAN SPRAY EQUIPMENT IMMEDIATELY WITH WATER. 6. Spray one (1) or two (2) full wet coat(s) of ready-to-spray Anti-chip Stone Abrasion material. 7. Mix and spray Ford approved basecoat material to hiding. Follow recommended flash time. 8. Mix and spray two (2) full wet coats of Ford approved clearcoat material. Follow recommended flash time. Anti-chip Stone Abrasion Materials: ^ Glasurit 1109-1240-6 Stone Chip Protector ^ Gravi-tex ^ Dominion Shure Seal Gravel Gard III ^ Dominion Shure Seal Rocker Gard 8949 ^ 3M Rocker Schutz ^ 3M Rocker Gard II ^ PPG RoadGard DX54 ^ Spies Hecker Stone Chip Protector 7100-7104 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-3-3 > Feb > 98 > Paint - Surface Defect Removal Without Repainting Technical Service Bulletin # 98-3-3 Date: 980216 Paint - Surface Defect Removal Without Repainting Article No. 98-3-3 02/16/98 PAINT - SURFACE DEFECT REMOVAL WITHOUT REPAINTING - SERVICE TIP FORD: 1997 ASPIRE, PROBE, THUNDERBIRD 1997-98 CONTOUR 1998 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1997 COUGAR 1997-98 MYSTIQUE 1998 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1997 AEROSTAR 1997-98 EXPEDITION, EXPLORER, F-150, F-250 LD, F-250 LD, MOUNTAINEER, RANGER, VILLAGER, WINDSTAR 1998 ECONOLINE, NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1997 AEROMAX, CARGO SERIES, F & B SERIES, L SERIES, LOUISVILLE ISSUE: Exterior paint surface maintenance or damage repair where the basecoat does not show through should be restored without repainting. The restoration of gloss and luster may be enhanced with new techniques and three new Ford approved materials. ACTION: The following procedure is applicable to repair surface conditions such as dirt particles, "orange peel," runs, sags, industrial fallout stains, swirl marks, and scratches. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Preparation The affected surface must be clean and dry to be repaired. Mask off adjacent panels, mouldings, stripe, and character lines as required. CAUTION: EYE PROTECTION SHOULD BE WORN. JEWELRY, WATCHES, AND BELT BUCKLES MUST BE REMOVED OR COVERED TO PREVENT ACCIDENTAL DAMAGE TO PAINT FINISH. NOTE: CHECK PAINT FILM THICKNESS BEFORE AND AFTER PERFORMANCE OF REPAIRS. MAXIMUM PAINT FILM REMOVAL IS 0.3 OF Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-3-3 > Feb > 98 > Paint - Surface Defect Removal Without Repainting > Page 9807 A MIL. NOTE: PERFORM A TRIAL REPAIR ON A SMALL AREA. FIRST, TRY A POLISH; IF THIS IS NOT SUCCESSFUL, TRY BUFFING WITH FORD MEDIUM DUTY BODY SHOP PAINT CLEANER (F6AZ-19530-BA) OR FORD HEAVY DUTY BODY SHOP PAINT CLEANER (F6AZ-19530-CA) AND, FINALLY, USE WET SANDING TO REMOVE THE CONDITION. USE THE MOST EFFECTIVE TECHNIQUE ON THE REMAINING AREAS. AN OUTLINE OF THE COMPLETE PROCEDURE AND REQUIRED MATERIALS FOLLOWS. Service Notes 1. Remove sanding marks with Ford Medium or Heavy Duty Body Shop Paint Cleaner. 2. Swirl marks, evident after buffing, may be removed by polishing with Ford Light Duty Body Shop Polish (F6AZ-19530-BA). 3. Remove light scratches and small dirt particles with a power buffer and Ford Medium Duty Body Shop Pain Cleaner followed by polishing with Ford Light Duty Body Shop Polish. 4. Remove deep scratches and heavy dirt particles or "orange peel" by wet sanding. Removing Scratches/Swirl Marks/Restore Dull Finish The Black and Decker Buffmaster(R) 5950 is the tool of choice. Variable speed buffers are available in a variety of buffing speeds. The recommended speed range is (1200-1750 rpm). 1. Apply a small amount of Ford Light Duty Body Shop Polish to the pad. ^ Always keep the face of the buffing pad completely flat to the surface, reducing the risk of buffer swirl marks. Watch your pad, especially on angled surfaces, to be certain that it stays flat ^ When "buffing out" oxidation or other paint defects with a cleaning material, use a liberal amount of material, slower buffing motion and added downward pressure to increase cutting action 2. When polishing, keep the pad flat against the surface. Do not bear down. The weight of the buffer is suffi6ient. CAUTION: DO NOT MIX PRODUCTS. USE A SEPARATE, DEDICATED BUFFING PAD FOR EACH PRODUCT TO ACHIEVE DESIRED RESULTS. Med. Scratches, Small Dirt Particles, Grind & Sanding Marks 1. Apply Ford Medium Duty Body Shop Paint Cleaner to the panel with a clean compound pad on the wheel. 2. Spread the product evenly and continue buffing until the condition is removed. 3. Keep the wheel flat to the surface and use light to moderate pressure and long strokes. 4. Periodically check the finish and add product as required. 5. When buffing is complete, polish the panel as described previously. Untreated wool cutting pads are the most effective cutting pads to use with Ford Heavy Duty Body Shop Paint Cleaner for removing paint defects and heavy oxidation. Following the use of a wool cutting pad, it may be necessary to polish the finish with a foam pad to remove the deep swirl marks. NOTE: ALWAYS KEEP THE PAD MOVING AND LIMIT YOUR STROKES OVER THE BLEMISH TO PREVENT EXCESSIVE HEAT BUILDUP AND POSSIBLE BURN-THROUGH. STOP IMMEDIATELY IF THE SURFACE BECOMES TOO HOT TO LAY THE PALM OF YOUR HAND ON IT. KEEP SURFACE TEMPERATURE BELOW 38°C (100°F). NOTE: HEAT BUILDUP: WHEN BUFFING CREATES EXCESSIVE HEAT, HAZING MAY APPEAR ACROSS THE SURFACE BEING BUFFED AND THE PRODUCT MAY DRY LIKE A FILM AND REFUSE TO BUFF OUT. TO REMEDY, WIPE THE AREA DOWN WITH COOL WATER, DRY THE SURFACE AND RESUME BUFFING, AT A LOWER RPM IF POSSIBLE. NOTE: STATIC: STATIC ELECTRICITY MAY BE PRESENT ON A PAINTED FIBERGLASS/PLASTIC SURFACE BEING BUFFED. THE MATERIAL MAY DRY LIKE A FILM OR TURN "GUMMY" AND BEGIN TO BALL UP. TO REMEDY, ATTACH A GROUNDING CLAMP TO THE SURFACE BEING BUFFED TO ELIMINATE THE STATIC CHARGE. Run and Sag Removal This procedure consists of shaving the run(s) or sag(s) flush with a commercial single edge razor blade, shaving file or sanding. NOTE: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-3-3 > Feb > 98 > Paint - Surface Defect Removal Without Repainting > Page 9808 IF IT IS NECESSARY TO SHAVE RUNS AND SAGS WITH A RAZOR BLADE, FIRST DULL THE CORNERS WITH SANDPAPER TO AVOID SCRATCHING THE ADJACENT AREA FINISH. 1. Lightly scrape the defect until the defect is level with the surface. 2. Wet sand or compound the surface to remove any small scratches. 3. Polish to complete the repair. Wet Sanding For Defect Removal ^ Typical paint defects that are repaired with this system include: dirt in paint, solvent "pop," cratering, "orange peel," drips, scratches, water spots, and acid rain ^ Always use the least abrasive (highest grit) sanding products possible to do this job The following wet sanding procedure utilizes light grit sandpaper or sanding blocks for removal of surface damage. These materials cut quickly, leaving a uniform finish requiring a minimum of buffing to restore gloss. 1. Mist or apply water on the area to be sanded. Continue to flush water on the surface during sanding for maximum lubrication. 2. Use sanding blocks or paper. Keep abrasion to the immediate area of the defect. Keep blocks in water when not in use. 3. If the cutting is too slow, switch to a lower grade block or paper and resume sanding. When 90% of the defect is removed, switch to a 2000 grade sand paper or sanding block to finish smoothing and prepare the surface for buffing. 4. Sanding blocks can be shaped to work on any angle. When the block is wet, rub it against a dry sanding block for shaping. 5. When using sanding papers, wrap the paper tightly around a backing pad. This pad evenly distributes pressure over the entire surface of the sanding paper. This creates a uniform sanding pattern. 6. Plan your strokes to limit the abrasion to the smallest area possible. 7. Always finish sanding with 2000 Grit Sanding Paper. 2000 grit paper will reduce the need for heavy compound, however, the area should be finished by using a cleaner that will remove the sanding scratches left by these papers. NOTE: IF MULTIPLE GRIT PAPERS ARE USED, IT IS A GOOD IDEA TO CHANGE THE DIRECTION OF SANDING STROKE TO ALLOW YOU TO SEE THAT THE PREVIOUS GRIT SCRATCH IS REMOVED. 8. Buff out sanding marks by applying Ford Medium Duty Body Shop Paint Cleaner with a "Foam" Cutting Pad (W7000). Follow with Ford Light Duty Body Shop Polish for a swirl-free gloss. General Techniques and Hints ^ "Foam" buffing pads yield maximum gloss and depth of color on all types of paint finishes without creating buffer swirl marks ^ Always apply product directly to pad, not to oxidized paint surface. Dry paint absorbs material into pores upon contact ^ Avoid short rapid strokes. Move the buffer slowly across the surface using long straight motions and overlap by 50% the buffing pattern left by the previous pass. This insures uniform coverage and allows both material and buffer to perform at maximum efficiency ^ Avoid buffing directly on raised character lines. The reduced paint film on these surfaces increases the risk of paint burn-through. It is best to buff up to them from each side ^ If a paint blemish remains after buffing, reapply a small amount of material over the blemish~ Confine your buffing strokes to the immediate area of the blemish while applying additional downward pressure and keeping the pad flat Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9809 Paint: By Symptom Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9810 ACTION To remove these particles/contaminates, use ONLY the following 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9811 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9812 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 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. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. 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 identitying 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9813 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 with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ 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 will be visible and may be felt. Decontamination Procedure Use Ford 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 Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./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 a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9814 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. Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9815 ACTION To remove these particles/contaminates, use ONLY the following 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9816 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9817 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 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. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. 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 identitying 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9818 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 with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ 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 will be visible and may be felt. Decontamination Procedure Use Ford 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 Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./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 a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9819 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. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications RAP Module Nuts ................................................................................................................................ ......................................................... 7 Nm (62 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 9824 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 9825 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 9826 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Disconnect the C257 and C256 Remote Anti-theft Personality (RAP) module electrical connectors. 3. Remove the nuts and the RAP module. NOTE: On Expedition and later build Navigators, the antenna is internal to the module and must be replaced as an assembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 9827 strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay Power Door Lock Relay: Locations All Lock Relay Body View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9832 Lock Relays The All Lock Relay is located in lock relays. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9833 Power Door Lock Relay: Locations All Unlock Relay Body View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9834 Lock Relays The All Un-Lock Relay is located in lock relays. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9835 Power Door Lock Relay: Locations Driver's Door Unlock Relay Body View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9836 Lock Relays The Driver's Unlock Relay is located in the lock relays. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9837 Power Door Lock Relay: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Memory Power Driver Seat Operation Power Seat Control Module: Description and Operation Memory Power Driver Seat Operation The memory driver seat feature allows the driver to program a personalized seat position that can be recalled using the memory switches or remote entry key fob. There are three memory settings possible. The outside rear view mirror positions are also stored and recalled with the power driver seat positions. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 9842 Power Seat Control Module: Description and Operation Memory Seat Module Driver Seat Module The power driver seat and power outside rear view mirrors are controlled by the Driver Seat Module (DSM) only when the vehicle is equipped with the programmable/recall memory option. The DSM system consists of the following components: ^ Driver seat module. ^ Driver memory seat switch. ^ Memory mirror switch. ^ Memory set switch. ^ Front vertical seat motor. ^ Rear vertical seat motor. ^ Driver horizontal seat motor. ^ LH heated memory mirror. ^ RH heated memory mirror. The DSM incorporates multiple functions into one module and offers diagnostics to easily locate and repair concerns affecting the subsystems that it controls. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 9843 Power Seat Control Module: Description and Operation Programming Seat Positions A power driver seat position can be stored at any time. The driver must move the seat to the desired position using the driver seat switch assembly. The driver must then depress the memory SET switch which activates the memory SET switch Light Emitting Diode (LED). Within five seconds (before the LED goes out), the driver must select a memory position. Memory 1 is selected by depressing memory switch 1. Memory 2 is selected by depressing memory switch 2. Memory 3 is selected by depressing both memory switch 1 and memory switch 2 simultaneously. If no memory switch input is received within the five second time limit, the operation is aborted and the memory SET switch LED is turned off. If one of the following inputs is received during the five secondprogramming limit, the operation is aborted and the memory SET switch LED is turned off: - Power driver seat switch. - Power outside rear view mirror switch. - Memory SET switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 9844 Power Seat Control Module: Description and Operation Recalling A Stored Seat Position NOTE: A memory recall can be initiated only if the vehicle is in PARK or NEUTRAL gear and the ignition switch is not in START. A memory recall in progress will not be affected by moving the ignition switch to START or by moving the gearshift lever out of PARK or NEUTRAL. Once the driver has stored the desired driver seat position, the driver can recall the setting by depressing the corresponding memory switch or by using a programmed remote entry transmitter. ^ The driver can recall the desired driver seat position by depressing one or both of the memory recall switches. Depressing memory switch 1 will initiate a recall of the power driver seat position stored in memory 1. Depressing memory switch 2 will initiate a recall of the power driver seat position stored in memory 2. Depressing memory switch 1 and memory switch 2 simultaneously will initiate a recall of the power driver seat position stored in memory 3. ^ A remote transmitter can be used to recall previously set memory positions. Transmitters are manufactured with an assigned personality number (1, 2, or 3) and are so designated on the back of the transmitter. The transmitter assigned with personality 1 is capable of recalling memory position 1 only. Similarly, the personality 2 and 3 transmitters can recall only memory positions 2 and 3 respectively. ^ Memory recall occurs when the UNLOCK switch is depressed on the transmitter. The second depression of the UNLOCK switch, which unlocks passenger doors, does not initiate a memory recall. ^ A memory recall in progress does not prohibit the initiation of another memory recall; the most recently requested memory recall will be executed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations Sunroof / Moonroof Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 9848 RPO Relay Block The Vent Window/Moonroof Relay is located in the regular production option relay block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 9849 Sunroof / Moonroof Relay: Testing and Inspection Relay Component Test Testing of an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove (unplug) the relay to be tested from the engine compartment fuse junction panel, I/P fuse junction panel or individual connector. Mini ISO Relay Use 73 Digital Multimeter to check for the continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 85 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. With 73 Digital Multimeter set in the volts position, check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85 and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair Sunroof / Moonroof Module: Service and Repair REMOVAL 1. Close the sliding roof panel. 2. Disconnect the battery ground cable. 3. Remove the access cover. 4. Slide the sliding roof panel module from the retaining bracket. 5. Disconnect the electrical connectors and remove the sliding roof panel module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair Sun Shade: Service and Repair REMOVAL 1. Remove the sliding roof panel. 2. Remove the water trough. 1 Remove the bolts. 2 Remove the water trough. 3. Flex the opening shield to remove the guides from the tracks and remove the opening shield. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications Sunroof / Moonroof Motor: Specifications Sliding Roof Panel Motor Bolts ............................................................................................................................................................ 4-6 Nm (36-53 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications > Page 9861 Moonroof Motor Assembly Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications > Page 9862 Sunroof / Moonroof Motor: Service and Repair REMOVAL 1. Remove the access cover. NOTE: The sliding roof panel should be in the closed position. 2. Remove the three bolts. 3. Disconnect the electrical connector and remove the sliding roof panel motor. INSTALLATION 1. Connect the electrical connector. NOTE: The sliding roof panel should be in the closed position. 2. Cycle the sliding roof panel motor until it stops in the closed position. 3. Remove the sliding roof panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications > Page 9863 4. Insert two 1/8 inch pins through both portions of the lifter assemblies. 5. Install the sliding roof panel motor. ^ Install the three bolts. NOTE: It may be necessary to rotate the sliding roof panel motor slightly to engage the drive splines. 6. Remove the pins. 7. Install the sliding roof panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations Sunroof / Moonroof Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations > Page 9867 RPO Relay Block The Vent Window/Moonroof Relay is located in the regular production option relay block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations > Page 9868 Sunroof / Moonroof Relay: Testing and Inspection Relay Component Test Testing of an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove (unplug) the relay to be tested from the engine compartment fuse junction panel, I/P fuse junction panel or individual connector. Mini ISO Relay Use 73 Digital Multimeter to check for the continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 85 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. With 73 Digital Multimeter set in the volts position, check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85 and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams Moonroof Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 9872 Sunroof / Moonroof Switch: Description and Operation When the roof sliding panel switch is rocked rearward, the sliding roof panel moves back into the storage space between the roof trim panel and the roof panel. The sliding roof panel can be moved to the fully closed position by rocking the roof sliding panel switch forward. When the sliding roof panel is in the fully closed position, the rear portion can be raised to provide ventilation by rocking the roof sliding panel switch forward. The sliding roof panel can be closed by rocking the roof sliding panel switch rearward. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 DISASSEMBLY 1. Remove the roof opening panel frame. 2. Remove the water trough. 1 Remove the bolts. 2 Remove the water trough. 3. Remove the water trough guide by sliding it back and lifting it outward at the notch in the tracks. ASSEMBLY 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Service and Repair Sunroof / Moonroof Module: Service and Repair REMOVAL 1. Close the sliding roof panel. 2. Disconnect the battery ground cable. 3. Remove the access cover. 4. Slide the sliding roof panel module from the retaining bracket. 5. Disconnect the electrical connectors and remove the sliding roof panel module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation > Memory Power Driver Seat Operation Seat Memory Switch: Description and Operation Memory Power Driver Seat Operation The memory driver seat feature allows the driver to program a personalized seat position that can be recalled using the memory switches or remote entry key fob. There are three memory settings possible. The outside rear view mirror positions are also stored and recalled with the power driver seat positions. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 9885 Seat Memory Switch: Description and Operation Programming Seat Positions A power driver seat position can be stored at any time. The driver must move the seat to the desired position using the driver seat switch assembly. The driver must then depress the memory SET switch which activates the memory SET switch Light Emitting Diode (LED). Within five seconds (before the LED goes out), the driver must select a memory position. Memory 1 is selected by depressing memory switch 1. Memory 2 is selected by depressing memory switch 2. Memory 3 is selected by depressing both memory switch 1 and memory switch 2 simultaneously. If no memory switch input is received within the five second time limit, the operation is aborted and the memory SET switch LED is turned off. If one of the following inputs is received during the five secondprogramming limit, the operation is aborted and the memory SET switch LED is turned off: - Power driver seat switch. - Power outside rear view mirror switch. - Memory SET switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 9886 Seat Memory Switch: Description and Operation Recalling A Stored Seat Position NOTE: A memory recall can be initiated only if the vehicle is in PARK or NEUTRAL gear and the ignition switch is not in START. A memory recall in progress will not be affected by moving the ignition switch to START or by moving the gearshift lever out of PARK or NEUTRAL. Once the driver has stored the desired driver seat position, the driver can recall the setting by depressing the corresponding memory switch or by using a programmed remote entry transmitter. ^ The driver can recall the desired driver seat position by depressing one or both of the memory recall switches. Depressing memory switch 1 will initiate a recall of the power driver seat position stored in memory 1. Depressing memory switch 2 will initiate a recall of the power driver seat position stored in memory 2. Depressing memory switch 1 and memory switch 2 simultaneously will initiate a recall of the power driver seat position stored in memory 3. ^ A remote transmitter can be used to recall previously set memory positions. Transmitters are manufactured with an assigned personality number (1, 2, or 3) and are so designated on the back of the transmitter. The transmitter assigned with personality 1 is capable of recalling memory position 1 only. Similarly, the personality 2 and 3 transmitters can recall only memory positions 2 and 3 respectively. ^ Memory recall occurs when the UNLOCK switch is depressed on the transmitter. The second depression of the UNLOCK switch, which unlocks passenger doors, does not initiate a memory recall. ^ A memory recall in progress does not prohibit the initiation of another memory recall; the most recently requested memory recall will be executed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Description and Operation > Memory Power Driver Seat Operation Power Seat Control Module: Description and Operation Memory Power Driver Seat Operation The memory driver seat feature allows the driver to program a personalized seat position that can be recalled using the memory switches or remote entry key fob. There are three memory settings possible. The outside rear view mirror positions are also stored and recalled with the power driver seat positions. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 9891 Power Seat Control Module: Description and Operation Memory Seat Module Driver Seat Module The power driver seat and power outside rear view mirrors are controlled by the Driver Seat Module (DSM) only when the vehicle is equipped with the programmable/recall memory option. The DSM system consists of the following components: ^ Driver seat module. ^ Driver memory seat switch. ^ Memory mirror switch. ^ Memory set switch. ^ Front vertical seat motor. ^ Rear vertical seat motor. ^ Driver horizontal seat motor. ^ LH heated memory mirror. ^ RH heated memory mirror. The DSM incorporates multiple functions into one module and offers diagnostics to easily locate and repair concerns affecting the subsystems that it controls. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 9892 Power Seat Control Module: Description and Operation Programming Seat Positions A power driver seat position can be stored at any time. The driver must move the seat to the desired position using the driver seat switch assembly. The driver must then depress the memory SET switch which activates the memory SET switch Light Emitting Diode (LED). Within five seconds (before the LED goes out), the driver must select a memory position. Memory 1 is selected by depressing memory switch 1. Memory 2 is selected by depressing memory switch 2. Memory 3 is selected by depressing both memory switch 1 and memory switch 2 simultaneously. If no memory switch input is received within the five second time limit, the operation is aborted and the memory SET switch LED is turned off. If one of the following inputs is received during the five secondprogramming limit, the operation is aborted and the memory SET switch LED is turned off: - Power driver seat switch. - Power outside rear view mirror switch. - Memory SET switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 9893 Power Seat Control Module: Description and Operation Recalling A Stored Seat Position NOTE: A memory recall can be initiated only if the vehicle is in PARK or NEUTRAL gear and the ignition switch is not in START. A memory recall in progress will not be affected by moving the ignition switch to START or by moving the gearshift lever out of PARK or NEUTRAL. Once the driver has stored the desired driver seat position, the driver can recall the setting by depressing the corresponding memory switch or by using a programmed remote entry transmitter. ^ The driver can recall the desired driver seat position by depressing one or both of the memory recall switches. Depressing memory switch 1 will initiate a recall of the power driver seat position stored in memory 1. Depressing memory switch 2 will initiate a recall of the power driver seat position stored in memory 2. Depressing memory switch 1 and memory switch 2 simultaneously will initiate a recall of the power driver seat position stored in memory 3. ^ A remote transmitter can be used to recall previously set memory positions. Transmitters are manufactured with an assigned personality number (1, 2, or 3) and are so designated on the back of the transmitter. The transmitter assigned with personality 1 is capable of recalling memory position 1 only. Similarly, the personality 2 and 3 transmitters can recall only memory positions 2 and 3 respectively. ^ Memory recall occurs when the UNLOCK switch is depressed on the transmitter. The second depression of the UNLOCK switch, which unlocks passenger doors, does not initiate a memory recall. ^ A memory recall in progress does not prohibit the initiation of another memory recall; the most recently requested memory recall will be executed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: Customer Interest Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: All Technical Service Bulletins Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage Valve Body: All Technical Service Bulletins A/T - Main Controls/Separator Plate/Gaskets Usage Article No. 98-16-8 08/17/98 TRANSMISSION - E4OD/4R100 - 1989-99 - MAIN CONTROLS, SEPARATOR PLATES AND SEPARATOR PLATE GASKETS USAGE CHART LIGHT TRUCK: 1989-96 BRONCO, F-150 1989-97 F SUPER DUTY, F-250 HD 1989-98 ECONOLINE, F-250 LD, F-35O 1997-98 EXPEDITION, F-150 1998 NAVIGATOR 1999 SUPER DUTY F SERIES Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage > Page 9912 This TSB article is being republished in its entirety to revise Figure 1. ISSUE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage > Page 9913 The Chart has been developed to assist in showing the complexity and compatibility of main controls, separator plates, and plate gaskets used for E4OD/4R100 transmissions. ACTION Refer to the Usage Chart for information showing the compatibility of main controls, separator plates, and plate gaskets. This TSB should not be used in place of the Parts Catalog. NOTE TO VERIFY CORRECT GASKET USAGE, REFER TO FIGURE 1 TO IDENTIFY THE SEPARATOR PLATE I.D. NOTCHES. THEN REFER TO THE CHART TO SEE WHICH GASKETS ARE COMPATIBLE WITH THE MAIN CONTROLS AND SEPARATOR PLATES BEING USED. CAUTION MIXING COMPONENTS OTHER THAN THOSE LISTED MAY CAUSE SHIFT CONCERNS AND/OR DAMAGE TO THE TRANSMISSION. REFER TO THE PARTS CATALOG FOR PROPER USAGE BY MODEL AND YEAR. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-9-21 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000, 590000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 98-9-20 > May > 98 > A/T - E4OD 4-1 Downshift During Forced 4-2 Downshift Valve Body: All Technical Service Bulletins A/T - E4OD 4-1 Downshift During Forced 4-2 Downshift Article No. 98-9-20 05/11/98 TRANSMISSION - E4OD - DOWNSHIFT DURING A FORCED 4-2 DOWNSHIFT BETWEEN 88-105 KM/H (55-65 MPH) - VEHICLES BUILT THROUGH 12/22/97 LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE Some vehicles may experience a 4-1 downshift when performing a forced 4-2 downshift (kickdown) between 88-105 km/h (55-65 mph) causing the engine rpm to increase higher than expected. This may be caused by internal leakage of fluid between the hydraulic circuits in the transmission case worm trail between the separator plate gasket and transmission case. ACTION Perform normal diagnostics as outlined in the appropriate Workshop Manual. If the concern is still present, replace the separator plate and gaskets. Refer to the Application Chart below and the appropriate Workshop Manual for replacement procedures. PART NUMBER PART NAME F8UZ-7A008-CA Separator Plate F81Z-7A008-EA Separator Plate F81Z-7C155-AA Gasket F81Z-7D100-AB Gasket OTHER APPLICABLE ARTICLES: 98-9-21 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 98O92OA Replace Separator Plate 2.1 Hrs. And Gasket DEALER CODING CONDITION BASIC PART NO. CODE 7A008, 7D100 42 OASIS CODES: 502000, 504000, 590000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage > Page 9923 This TSB article is being republished in its entirety to revise Figure 1. ISSUE Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage > Page 9924 The Chart has been developed to assist in showing the complexity and compatibility of main controls, separator plates, and plate gaskets used for E4OD/4R100 transmissions. ACTION Refer to the Usage Chart for information showing the compatibility of main controls, separator plates, and plate gaskets. This TSB should not be used in place of the Parts Catalog. NOTE TO VERIFY CORRECT GASKET USAGE, REFER TO FIGURE 1 TO IDENTIFY THE SEPARATOR PLATE I.D. NOTCHES. THEN REFER TO THE CHART TO SEE WHICH GASKETS ARE COMPATIBLE WITH THE MAIN CONTROLS AND SEPARATOR PLATES BEING USED. CAUTION MIXING COMPONENTS OTHER THAN THOSE LISTED MAY CAUSE SHIFT CONCERNS AND/OR DAMAGE TO THE TRANSMISSION. REFER TO THE PARTS CATALOG FOR PROPER USAGE BY MODEL AND YEAR. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-9-21 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000, 590000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9929 Power Seat Switch: Specifications Seat Regulator Control Switch Screws ................................................................................................................................................... 1-3 Nm (9-26 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9930 Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9931 Power Seat Switch: Testing and Inspection Left Front Seat Control Switch - Component Testing Procedure (Part 1 Of 2) Left Front Seat Control Switch - Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9932 Left Front Seat Control Switch - Terminal Locations Left Front Seat Control Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9933 Power Seat Switch: Service and Repair REMOVAL NOTE: Driver side shown, passenger side similar. 1. Disconnect the battery ground cable. 2. Remove the front seat back adjust handle. 1 Remove the screw. 2 Remove the front seat back adjust handle. 3. Pull to remove the front seat lumbar support handle. 4. Remove the front seat track shield screws. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9934 5. Remove the pushpin on the back of the front seat track shield. 6. Remove the screws on the bottom of the front seat track shield. 7. Disconnect the seat regulator control switch from the front of the front seat track shield. 1 Remove the screws. 2 Disconnect the seat regulator control switch. 8. Disconnect the seat regulator control switch electrical connector and remove the seat regulator control switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9935 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 98-13-13 > Jul > 98 > Front Leather Seats - Wear Prematurely Seat Cover: Customer Interest Front Leather Seats - Wear Prematurely Article No. 98-13-13 07/06/98 SEATS - FRONT LEATHER SEATS WEAR PREMATURELY - VEHICLES BUILT THROUGH 12/16/97 LIGHT TRUCK: 1997-98 EXPEDITION ISSUE The front leather seats may prematurely wear or wrinkle on some vehicles. This may be caused by the seat cover sticking to the foam cushion. ACTION Replace the leather seat cover with a revised seat cover which includes angel hair to be placed between the cover and foam cushion. The angel hair allows the leather cover to slide with the occupant on the foam cushion, reducing the possibility of premature wear. Refer to the text for details. For concerns of front leather seats wearing or wrinkling prematurely, use the appropriate service Seat Cover Kit (listed in the Parts Block), and obtain locally seven (7) hog rings per seat. Follow instructions (SK F85B-16A091-AA) included in the kit. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981313A Install Leather Front Seat 1.0 Hr. Kit (One) 981313B Install Leather Front Seat 1.9 Hrs. Kit (Both) DEALER CODING CONDITION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 98-13-13 > Jul > 98 > Front Leather Seats - Wear Prematurely > Page 9944 BASIC PART NO. CODE 7860050 - 7860051 30 OASIS CODES: 101000, 107000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 98-17-1 > Sep > 98 > Seat Leather - Cleaning Procedure Tips Seat Cover: All Technical Service Bulletins Seat Leather - Cleaning Procedure Tips Article No. 98-17-1 09/01/98 SEAT - LEATHER CLEANING PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 THUNDERBIRD 1984-98 CROWN VICTORIA, ESCORT, MUSTANG 1986-98 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1984-94 TOPAZ 1984-97 COUGAR 1984-98 GRAND MARQUIS, TRACER 1984-99 TOWN CAR 1986-98 SABLE 1993-98 MARK VIII 1995-98 MYSTIQUE 1995-99 CONTINENTAL 1999 COUGAR LIGHT TRUCK: 1983-98 RANGER 1984-96 BRONCO 1984-97 F-250 HD 1984-98 ECONOLINE, F-150, F-250 LD 1986-97 AEROSTAR 1991-98 EXPLORER 1993-98 VILLAGER 1996-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to include the latest level parts and to include a revised Service Procedure. ISSUE The following TSB contains information regarding the cleaning of interior leather seats and trim. Improper cleaning procedures may damage the leather. If seats are not cleaned on a regular basis (every 4-6 weeks), normal wear and tear can cause excessive soiling. ACTION Ford Motor Company has developed a new kit (Deluxe Leather Care Kit - F8AZ-19G253-AA) to clean soiled seats without damaging the top coat of the leather. The kit contains a leather and vinyl cleaner along with a specially formulated sponge. Refer to the text for cleaning leather seats and trim. The Deluxe Leather Care Kit has been tested and approved for use on all Ford and Lincoln/Mercury leather and vinyl seating surfaces, and if used as directed, should be used for service repairs. Many household cleaners and sponges are too harsh to be used on leather and may actually cause permanent damage to the surface. Use this material on leather and vinyl seats that: ^ show excessive soiling ^ have been stained with coffee, lipstick, etc. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 98-17-1 > Sep > 98 > Seat Leather - Cleaning Procedure Tips > Page 9950 Refer to the instructions included in the kit for specific application procedures. After cleaning surface with cleaner and sponge, wipe area with water and a cotton cloth. NOTE AVOID EXCESSIVE APPLICATION OF CLEANER ALONG STITCHING. PART NUMBER PART NAME F8AZ-19G253-AA Deluxe Leather Care Kit OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-14-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 101000, 107000, 190000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 98-13-13 > Jul > 98 > Front Leather Seats - Wear Prematurely Seat Cover: All Technical Service Bulletins Front Leather Seats - Wear Prematurely Article No. 98-13-13 07/06/98 SEATS - FRONT LEATHER SEATS WEAR PREMATURELY - VEHICLES BUILT THROUGH 12/16/97 LIGHT TRUCK: 1997-98 EXPEDITION ISSUE The front leather seats may prematurely wear or wrinkle on some vehicles. This may be caused by the seat cover sticking to the foam cushion. ACTION Replace the leather seat cover with a revised seat cover which includes angel hair to be placed between the cover and foam cushion. The angel hair allows the leather cover to slide with the occupant on the foam cushion, reducing the possibility of premature wear. Refer to the text for details. For concerns of front leather seats wearing or wrinkling prematurely, use the appropriate service Seat Cover Kit (listed in the Parts Block), and obtain locally seven (7) hog rings per seat. Follow instructions (SK F85B-16A091-AA) included in the kit. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981313A Install Leather Front Seat 1.0 Hr. Kit (One) 981313B Install Leather Front Seat 1.9 Hrs. Kit (Both) DEALER CODING CONDITION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 98-13-13 > Jul > 98 > Front Leather Seats - Wear Prematurely > Page 9955 BASIC PART NO. CODE 7860050 - 7860051 30 OASIS CODES: 101000, 107000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 98-17-1 > Sep > 98 > Seat Leather - Cleaning Procedure Tips Seat Cover: All Technical Service Bulletins Seat Leather - Cleaning Procedure Tips Article No. 98-17-1 09/01/98 SEAT - LEATHER CLEANING PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 THUNDERBIRD 1984-98 CROWN VICTORIA, ESCORT, MUSTANG 1986-98 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1984-94 TOPAZ 1984-97 COUGAR 1984-98 GRAND MARQUIS, TRACER 1984-99 TOWN CAR 1986-98 SABLE 1993-98 MARK VIII 1995-98 MYSTIQUE 1995-99 CONTINENTAL 1999 COUGAR LIGHT TRUCK: 1983-98 RANGER 1984-96 BRONCO 1984-97 F-250 HD 1984-98 ECONOLINE, F-150, F-250 LD 1986-97 AEROSTAR 1991-98 EXPLORER 1993-98 VILLAGER 1996-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to include the latest level parts and to include a revised Service Procedure. ISSUE The following TSB contains information regarding the cleaning of interior leather seats and trim. Improper cleaning procedures may damage the leather. If seats are not cleaned on a regular basis (every 4-6 weeks), normal wear and tear can cause excessive soiling. ACTION Ford Motor Company has developed a new kit (Deluxe Leather Care Kit - F8AZ-19G253-AA) to clean soiled seats without damaging the top coat of the leather. The kit contains a leather and vinyl cleaner along with a specially formulated sponge. Refer to the text for cleaning leather seats and trim. The Deluxe Leather Care Kit has been tested and approved for use on all Ford and Lincoln/Mercury leather and vinyl seating surfaces, and if used as directed, should be used for service repairs. Many household cleaners and sponges are too harsh to be used on leather and may actually cause permanent damage to the surface. Use this material on leather and vinyl seats that: ^ show excessive soiling ^ have been stained with coffee, lipstick, etc. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 98-17-1 > Sep > 98 > Seat Leather - Cleaning Procedure Tips > Page 9961 Refer to the instructions included in the kit for specific application procedures. After cleaning surface with cleaner and sponge, wipe area with water and a cotton cloth. NOTE AVOID EXCESSIVE APPLICATION OF CLEANER ALONG STITCHING. PART NUMBER PART NAME F8AZ-19G253-AA Deluxe Leather Care Kit OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-14-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 101000, 107000, 190000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Door Left Power Door Lock Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Door > Page 9967 Right Power Door Lock Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: Customer Interest Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: All Technical Service Bulletins Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9984 Power Seat Switch: Specifications Seat Regulator Control Switch Screws ................................................................................................................................................... 1-3 Nm (9-26 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9985 Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9986 Power Seat Switch: Testing and Inspection Left Front Seat Control Switch - Component Testing Procedure (Part 1 Of 2) Left Front Seat Control Switch - Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9987 Left Front Seat Control Switch - Terminal Locations Left Front Seat Control Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9988 Power Seat Switch: Service and Repair REMOVAL NOTE: Driver side shown, passenger side similar. 1. Disconnect the battery ground cable. 2. Remove the front seat back adjust handle. 1 Remove the screw. 2 Remove the front seat back adjust handle. 3. Pull to remove the front seat lumbar support handle. 4. Remove the front seat track shield screws. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9989 5. Remove the pushpin on the back of the front seat track shield. 6. Remove the screws on the bottom of the front seat track shield. 7. Disconnect the seat regulator control switch from the front of the front seat track shield. 1 Remove the screws. 2 Disconnect the seat regulator control switch. 8. Disconnect the seat regulator control switch electrical connector and remove the seat regulator control switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9990 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Description and Operation > Memory Power Driver Seat Operation Seat Memory Switch: Description and Operation Memory Power Driver Seat Operation The memory driver seat feature allows the driver to program a personalized seat position that can be recalled using the memory switches or remote entry key fob. There are three memory settings possible. The outside rear view mirror positions are also stored and recalled with the power driver seat positions. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 9995 Seat Memory Switch: Description and Operation Programming Seat Positions A power driver seat position can be stored at any time. The driver must move the seat to the desired position using the driver seat switch assembly. The driver must then depress the memory SET switch which activates the memory SET switch Light Emitting Diode (LED). Within five seconds (before the LED goes out), the driver must select a memory position. Memory 1 is selected by depressing memory switch 1. Memory 2 is selected by depressing memory switch 2. Memory 3 is selected by depressing both memory switch 1 and memory switch 2 simultaneously. If no memory switch input is received within the five second time limit, the operation is aborted and the memory SET switch LED is turned off. If one of the following inputs is received during the five secondprogramming limit, the operation is aborted and the memory SET switch LED is turned off: - Power driver seat switch. - Power outside rear view mirror switch. - Memory SET switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Description and Operation > Memory Power Driver Seat Operation > Page 9996 Seat Memory Switch: Description and Operation Recalling A Stored Seat Position NOTE: A memory recall can be initiated only if the vehicle is in PARK or NEUTRAL gear and the ignition switch is not in START. A memory recall in progress will not be affected by moving the ignition switch to START or by moving the gearshift lever out of PARK or NEUTRAL. Once the driver has stored the desired driver seat position, the driver can recall the setting by depressing the corresponding memory switch or by using a programmed remote entry transmitter. ^ The driver can recall the desired driver seat position by depressing one or both of the memory recall switches. Depressing memory switch 1 will initiate a recall of the power driver seat position stored in memory 1. Depressing memory switch 2 will initiate a recall of the power driver seat position stored in memory 2. Depressing memory switch 1 and memory switch 2 simultaneously will initiate a recall of the power driver seat position stored in memory 3. ^ A remote transmitter can be used to recall previously set memory positions. Transmitters are manufactured with an assigned personality number (1, 2, or 3) and are so designated on the back of the transmitter. The transmitter assigned with personality 1 is capable of recalling memory position 1 only. Similarly, the personality 2 and 3 transmitters can recall only memory positions 2 and 3 respectively. ^ Memory recall occurs when the UNLOCK switch is depressed on the transmitter. The second depression of the UNLOCK switch, which unlocks passenger doors, does not initiate a memory recall. ^ A memory recall in progress does not prohibit the initiation of another memory recall; the most recently requested memory recall will be executed. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Moonroof Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 10000 Sunroof / Moonroof Switch: Description and Operation When the roof sliding panel switch is rocked rearward, the sliding roof panel moves back into the storage space between the roof trim panel and the roof panel. The sliding roof panel can be moved to the fully closed position by rocking the roof sliding panel switch forward. When the sliding roof panel is in the fully closed position, the rear portion can be raised to provide ventilation by rocking the roof sliding panel switch forward. The sliding roof panel can be closed by rocking the roof sliding panel switch rearward. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > Customer Interest for Tailgate: > 04-18-11 > Sep > 04 > Body - Corrosion At Bottom of Door or Tailgate Tailgate: Customer Interest Body - Corrosion At Bottom of Door or Tailgate TSB 04-18-11 09/20/04 BODY - CORROSION AT BOTTOM OF DOOR OR TAILGATE HEM FLANGE - REPAIR PROCEDURE FORD: 1997-2001 Taurus 2000-2001 Focus 1997-2001 Expedition, F-250 LD, Windstar, F-Series LINCOLN: 1998-2001 Navigator MERCURY: 1997-2001 Sable This article supersedes TSB 01-09-8 to update the vehicle line and model year coverage and service procedure. ISSUE Some vehicles may exhibit corrosion at the hem flange at bottom of any door/tailgate where the outer panel is folded over the inner panel. ACTION Repair corrosion at the hem flange using special hem flange tools. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE READ THIS REPAIR PROCEDURE COMPLETELY BEFORE PERFORMING ANY SERVICE ACTIONS. NOTE THE USE OF FORD OR MOTORCRAFT BRAND PRODUCTS ARE MANDATORY ON ALL REPAIR CLAIMS PAID BY FORD UNLESS OTHERWISE SPECIFIED IN EMISSIONS, SAFETY RECALLS, OWNER NOTIFICATION PROGRAMS, TSB'S OR OTHER COMPANY PUBLICATIONS. THE COST OF NON-FORD/MOTORCRAFT PRODUCTS USED FOR A WARRANTY, ESP/ESC OR AWA REPAIR WITHOUT JUSTIFYING THEIR USE (SUCH AS EMERGENCY REPAIR) IS NOT REIMBURSABLE. EXAMPLES OF FORD PRODUCTS ARE ADHESIVES, SEALERS, SOLVENTS, CLEANERS, WASHES, AND OTHER SPECIAL PRODUCTS LISTED IN THE FORD CAR CARE PRODUCTS MANUAL. NOTE TECHNICIANS SHOULD WEAR THE APPROPRIATE EYE, HAND AND HEARING PROTECTION WHILE PERFORMING THESE REPAIR PROCEDURES. ADHESIVES AND SEALERS USED IN THESE PROCEDURES SHOULD BE USED IN A WELL-VENTILATED AREA. 1. Inspect the inside of the door/tailgate at the lower edge only for corrosion/bubbling. 2. Follow the Workshop Manual procedure for the removal of the interior door panel or tailgate and tailgate moldings. 3. Use shop air to blow out the drain holes in the bottom of the door/tailgate and apply 25 mm (1") tape to the outer skin at the bottom to prevent scuffing. 4. Use a hammer and screwdriver to slightly lift the corner of the hem flange. 5. Insert TOOL 501-078/1(RT) or TOOL 501-078/2(LT) in an air impact gun (620 kPa (90 psi) air pressure is required for consistent tool operation). Using the tool lift the hem flange continuing across the bottom of the door/tailgate and stop just before the end. 6. Use an angle grinder or wire brush to remove all corrosion on the bottom of the hem flange and inner door/tailgate panel. Follow by blowing off with compressed air. 7. Using appropriate hand protection, brush on Corrosion Converter (Sem # 69508) on the corroded area. Use light coat and let flash dry 2-5 minutes. Follow by using a damp cloth to wipe off corrosion residue. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > Customer Interest for Tailgate: > 04-18-11 > Sep > 04 > Body - Corrosion At Bottom of Door or Tailgate > Page 10009 8. Sand with a DA sander using 360 grit sand paper the lower areas of the door/tailgate where paint was disturbed, keeping the repair area small. Feather edge for a paint blend as necessary. Blow off the panel with clean compressed air. Clean the panels with wax and remover. 9. Mix and brush on Ford approved epoxy or self-etching primer to all bare hem flange areas on the bottom of the door/tailgate. Bake at 140°F (60° C) panel temperature per manufacturers label instructions. 10. Install the Motorcraft TA-1 adhesive cartridge into the application gun 501-040. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components. 11. Apply the adhesive between the hem flange and bottom of the inner door/tailgate panel. Work time is 45 minutes at 70°F (21°C). Adhesive cure time is 8 hours. 12. Use TOOL 501-080 to re-hem (close down) the hem flange. Start in a corner, and insert the center of the tool over the area to close down and hit with a hammer. 13. Install the Motorcraft TA-2 urethane cartridge into the application gun 501-040. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components. 14. Apply Motorcraft TA-2 urethane seam sealer around the door/tailgate hem flange to give a finished appearance. 15. Remove any residual sealer with adhesive remover. Sealer is paintable in 10 minutes and within 24 hours. 16. Mask the door/tailgate for color application. 17. Mix and apply Ford approved basecoat color to the inside of the door/tailgate area and allow material to flash off. 18. Mix and apply Ford approved clearcoat to inside of the door/tailgate and bake at 140°F (60°C) panel temperature per following manufacturers recommended baking time. 19. Spray Dominion Sure Seal Amber anti corrosion coating (24011) to the inside of the door/tailgate at the hem location. Do not plug drain holes. 20. Demask the vehicle and, reinstall the inner door panel or tailgate moldings. SPECIAL TOOLS ^ 501-078/1 RH Hem Opening Tool (Tools are direct ship from O.T.C.) ^ 501-078/2 LH Hem Opening Tool ^ 501-080 Hem Closing Tool ^ 501-040 Adhesive Gun (Adhesive Gun not included in kits. This is a commonly used commercially available gun. Must be ordered separately from Rotunda.) PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate: > 04-18-11 > Sep > 04 > Body - Corrosion At Bottom of Door or Tailgate Tailgate: All Technical Service Bulletins Body - Corrosion At Bottom of Door or Tailgate TSB 04-18-11 09/20/04 BODY - CORROSION AT BOTTOM OF DOOR OR TAILGATE HEM FLANGE - REPAIR PROCEDURE FORD: 1997-2001 Taurus 2000-2001 Focus 1997-2001 Expedition, F-250 LD, Windstar, F-Series LINCOLN: 1998-2001 Navigator MERCURY: 1997-2001 Sable This article supersedes TSB 01-09-8 to update the vehicle line and model year coverage and service procedure. ISSUE Some vehicles may exhibit corrosion at the hem flange at bottom of any door/tailgate where the outer panel is folded over the inner panel. ACTION Repair corrosion at the hem flange using special hem flange tools. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE READ THIS REPAIR PROCEDURE COMPLETELY BEFORE PERFORMING ANY SERVICE ACTIONS. NOTE THE USE OF FORD OR MOTORCRAFT BRAND PRODUCTS ARE MANDATORY ON ALL REPAIR CLAIMS PAID BY FORD UNLESS OTHERWISE SPECIFIED IN EMISSIONS, SAFETY RECALLS, OWNER NOTIFICATION PROGRAMS, TSB'S OR OTHER COMPANY PUBLICATIONS. THE COST OF NON-FORD/MOTORCRAFT PRODUCTS USED FOR A WARRANTY, ESP/ESC OR AWA REPAIR WITHOUT JUSTIFYING THEIR USE (SUCH AS EMERGENCY REPAIR) IS NOT REIMBURSABLE. EXAMPLES OF FORD PRODUCTS ARE ADHESIVES, SEALERS, SOLVENTS, CLEANERS, WASHES, AND OTHER SPECIAL PRODUCTS LISTED IN THE FORD CAR CARE PRODUCTS MANUAL. NOTE TECHNICIANS SHOULD WEAR THE APPROPRIATE EYE, HAND AND HEARING PROTECTION WHILE PERFORMING THESE REPAIR PROCEDURES. ADHESIVES AND SEALERS USED IN THESE PROCEDURES SHOULD BE USED IN A WELL-VENTILATED AREA. 1. Inspect the inside of the door/tailgate at the lower edge only for corrosion/bubbling. 2. Follow the Workshop Manual procedure for the removal of the interior door panel or tailgate and tailgate moldings. 3. Use shop air to blow out the drain holes in the bottom of the door/tailgate and apply 25 mm (1") tape to the outer skin at the bottom to prevent scuffing. 4. Use a hammer and screwdriver to slightly lift the corner of the hem flange. 5. Insert TOOL 501-078/1(RT) or TOOL 501-078/2(LT) in an air impact gun (620 kPa (90 psi) air pressure is required for consistent tool operation). Using the tool lift the hem flange continuing across the bottom of the door/tailgate and stop just before the end. 6. Use an angle grinder or wire brush to remove all corrosion on the bottom of the hem flange and inner door/tailgate panel. Follow by blowing off with compressed air. 7. Using appropriate hand protection, brush on Corrosion Converter (Sem # 69508) on the corroded area. Use light coat and let flash dry 2-5 minutes. Follow by using a damp cloth to wipe off corrosion residue. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate: > 04-18-11 > Sep > 04 > Body - Corrosion At Bottom of Door or Tailgate > Page 10015 8. Sand with a DA sander using 360 grit sand paper the lower areas of the door/tailgate where paint was disturbed, keeping the repair area small. Feather edge for a paint blend as necessary. Blow off the panel with clean compressed air. Clean the panels with wax and remover. 9. Mix and brush on Ford approved epoxy or self-etching primer to all bare hem flange areas on the bottom of the door/tailgate. Bake at 140°F (60° C) panel temperature per manufacturers label instructions. 10. Install the Motorcraft TA-1 adhesive cartridge into the application gun 501-040. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components. 11. Apply the adhesive between the hem flange and bottom of the inner door/tailgate panel. Work time is 45 minutes at 70°F (21°C). Adhesive cure time is 8 hours. 12. Use TOOL 501-080 to re-hem (close down) the hem flange. Start in a corner, and insert the center of the tool over the area to close down and hit with a hammer. 13. Install the Motorcraft TA-2 urethane cartridge into the application gun 501-040. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components. 14. Apply Motorcraft TA-2 urethane seam sealer around the door/tailgate hem flange to give a finished appearance. 15. Remove any residual sealer with adhesive remover. Sealer is paintable in 10 minutes and within 24 hours. 16. Mask the door/tailgate for color application. 17. Mix and apply Ford approved basecoat color to the inside of the door/tailgate area and allow material to flash off. 18. Mix and apply Ford approved clearcoat to inside of the door/tailgate and bake at 140°F (60°C) panel temperature per following manufacturers recommended baking time. 19. Spray Dominion Sure Seal Amber anti corrosion coating (24011) to the inside of the door/tailgate at the hem location. Do not plug drain holes. 20. Demask the vehicle and, reinstall the inner door panel or tailgate moldings. SPECIAL TOOLS ^ 501-078/1 RH Hem Opening Tool (Tools are direct ship from O.T.C.) ^ 501-078/2 LH Hem Opening Tool ^ 501-080 Hem Closing Tool ^ 501-040 Adhesive Gun (Adhesive Gun not included in kits. This is a commonly used commercially available gun. Must be ordered separately from Rotunda.) PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems Technical Service Bulletin # 98-9-13 Date: 980511 Body/Frame - Water Leaks Causing Electrical Problems Article No. 98-9-13 05/11/98 ^ WATER LEAKS - VARIOUS AREAS OF VEHICLE ^ ELECTRICAL - ACCESSORIES FUNCTIONING IMPROPERLY DUE TO WATER LEAKS ^ LAMPS - WARNING LAMPS ILLUMINATED DUE TO WATER LEAKS LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to add F-150, F-250 LD, and Navigator vehicles, and to revise the text and art accordingly. ISSUE Water leaks in various areas of the vehicle as identified below may be causing electrical concerns such as: ^ Warning lamps illuminating, and/or ^ Improper wiper operation, and/or ^ Improper function of electrical accessories The water leaks may be caused by sealer skips, unseated grommets, and/or clogged drain tubes. ACTION Repair the water leaks. Refer to the following Service Procedures for details on: ^ Windshield Leaks ^ Cowl Top Leaks ^ Cowl Side-to-Door Opening Panel Leaks ^ Cowl Side-to-Dash Panel Leaks ^ Moon roof Leaks ^ Grommets The following procedures may include using a seam sealer for repairs. Recommended seam sealers are: Company Part Name Phone Number 3M Ultrapro Seam Sealer (612) 733-5547 - US Kent Uniweld Seam Sealer (800) 654-6333 - US (800) 663-2800 - Canada OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-19-15 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10025 980913A Windshield Leaks Service 0.5 Hr. Procedure 980913B Additional Time If Leaf 0.4 Hr. Screen Must Be Removed (Used With Operation A) 980913C Cowl Top Leaks Service 1.3 Hrs. Procedure 980913D Cowl Side-To-Door 1.9 Hrs. Opening Panel Leaks Service Procedure 980913E Cowl Side-To-Dash Panel 0.4 Hr. Leaks Service Procedure 980913F Moonroof Leaks Service 0.4 Hr. Procedure 980913G Grommets Service 0.4 Hr. Procedure DEALER CODING CONDITION BASIC PART NO. CODE 18812 GROMMET(S) LEAKS 68 7801610 COWL TOP LEAKS (DASH PANEL) 68 7802012 COWL TOP LEAKS (OUTER) 68 7802018 COWL SIDE TO-DASH PANEL LEAKS 68 7802039 COWL SIDE-TO-DOOR OPENING PANEL LEAKS 68 7803100 WINDSHIELD LEAKS 68 78502C53 MOON ROOF LEAKS 68 OASIS CODES: 110000,190000, 202000, 203000, 205000, 206000 Windshield Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10026 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10027 Refer To Figures 1, 2, and 3 1. Remove A-pillar mouldings, rocker panel scuff plates, and cowl lower scuff plates. Refer to the appropriate Workshop Manual, Section 501-05. 2. Apply a water hose at the bottom center of the windshield and slowly move outboard at a rate of 305 mm (1 foot) per 15-20 seconds. Then move up one side, inboard along top of header to the center. Lift the moulding at top of windshield to allow water to pass through windshield moulding. NOTE A NARROW NYLON TIP ON THE END OF THE HOSE WILL ALLOW THE OPERATOR TO EASILY SLIDE THE TIP UNDER THE MOULDING AND SLOWLY MOVE IT ALONG THE INSIDE SURFACE. 3. To determine if water is entering, have an observer use a flashlight to watch for water as the hose is being moved. The observer should start looking at the dash back panel by pulling back the dash insulator pad above the water location. 4. If a leak is detected, document the location and path for future reference. 5. Fill any voids with pumpable Butyl Sealer. NOTE TO REPAIR WATER LEAKS FOUND AT THE BASE OF THE WINDSHIELD, THE LEAF SCREEN MUST FIRST BE REMOVED. Cowl Top Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10028 Refer To Figure 4 1. Remove the leaf screen by referring to the appropriate Workshop Manual, Section 501-02. 2. Spray water into cowl top-to-dash panel seam. Spray for up to 20 minutes. 3. Inspect the inner dash panel for water intrusion, starting at the bottom of the cowl area. 4. With the trim rocker cover and kick plate removed, pull back carpet and inspect for water. 5. If no water is found, look in the area of the cross car beam and/or lower windshield "VIN tag" area. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10029 6. Seal inner cowl with seam sealer. Cowl Side-to-Door Opening Panel Leaks Service Procedure Refer To Figure 5 1. Remove the left front tire. 2. Remove the inner fender splash shield from the left front fender. Refer to the appropriate Workshop Manual, Section 501-02, for details. 3. Remove the grille by referring to the Workshop Manual, Section 501-08. 4. Remove the left front fender by referring to the Workshop Manual, Section 501-02. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10030 5. Test with water. 6. Apply seam sealer along the interface between the cowl and the dash panel. This area can be reached through the access hole located near the top hinge for the front door. 7. Reassemble in reverse order. 8. Apply paint protection to fender bolts. Cowl Side-to-Dash Panel Leaks Service Procedure Refer To Figure 6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10031 1. Remove rocker cover and lower scuff panel by referring to the appropriate Workshop Manual, Section 501-05. 2. Inspect dash panel-to-cowl side inner sealer for skips and/or missing sealer. 3. Test with water at the top of the cowl/leaf screen area and inspect the vehicle for water entry. 4. Apply seam sealer along the interface between the cowl, dash, and floor panel. Moonroof Leaks Service Procedure Refer To Figure 7 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10032 1. Before beginning any diagnosis, contact the Webasto Tech Hotline at (800) 995-5911 Monday-Friday, 9AM-6PM EST. 2. Cycle moonroof to open position. 3. Check for proper drain tube action by pouring approximately 1.8L (6 oz) of water into trough at each side. 4. If tubes appear to be draining properly, remove the interior A-pillar trim and sun visors. Refer to the appropriate Workshop Manual, Section 501-05. 5. Pull down the headliner slightly and inspect moonroof drain tubes for kinks and/or twists. The drain tubes must be free from any bends or obstruction of water flow. 6. Straighten or cut drain tubes to proper length to allow for free draining. Grommets Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10033 Refer To Figure 8 1. Check for missing or improperly seated grommets in the following areas: ^ Antenna grommet on passenger side cowl ^ Park brake cable grommet on driver side cowl ^ Overall instrument panel grommets 2. Reseat any loose grommets or replace any missing grommets. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems Technical Service Bulletin # 98-9-13 Date: 980511 Body/Frame - Water Leaks Causing Electrical Problems Article No. 98-9-13 05/11/98 ^ WATER LEAKS - VARIOUS AREAS OF VEHICLE ^ ELECTRICAL - ACCESSORIES FUNCTIONING IMPROPERLY DUE TO WATER LEAKS ^ LAMPS - WARNING LAMPS ILLUMINATED DUE TO WATER LEAKS LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to add F-150, F-250 LD, and Navigator vehicles, and to revise the text and art accordingly. ISSUE Water leaks in various areas of the vehicle as identified below may be causing electrical concerns such as: ^ Warning lamps illuminating, and/or ^ Improper wiper operation, and/or ^ Improper function of electrical accessories The water leaks may be caused by sealer skips, unseated grommets, and/or clogged drain tubes. ACTION Repair the water leaks. Refer to the following Service Procedures for details on: ^ Windshield Leaks ^ Cowl Top Leaks ^ Cowl Side-to-Door Opening Panel Leaks ^ Cowl Side-to-Dash Panel Leaks ^ Moon roof Leaks ^ Grommets The following procedures may include using a seam sealer for repairs. Recommended seam sealers are: Company Part Name Phone Number 3M Ultrapro Seam Sealer (612) 733-5547 - US Kent Uniweld Seam Sealer (800) 654-6333 - US (800) 663-2800 - Canada OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-19-15 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10039 980913A Windshield Leaks Service 0.5 Hr. Procedure 980913B Additional Time If Leaf 0.4 Hr. Screen Must Be Removed (Used With Operation A) 980913C Cowl Top Leaks Service 1.3 Hrs. Procedure 980913D Cowl Side-To-Door 1.9 Hrs. Opening Panel Leaks Service Procedure 980913E Cowl Side-To-Dash Panel 0.4 Hr. Leaks Service Procedure 980913F Moonroof Leaks Service 0.4 Hr. Procedure 980913G Grommets Service 0.4 Hr. Procedure DEALER CODING CONDITION BASIC PART NO. CODE 18812 GROMMET(S) LEAKS 68 7801610 COWL TOP LEAKS (DASH PANEL) 68 7802012 COWL TOP LEAKS (OUTER) 68 7802018 COWL SIDE TO-DASH PANEL LEAKS 68 7802039 COWL SIDE-TO-DOOR OPENING PANEL LEAKS 68 7803100 WINDSHIELD LEAKS 68 78502C53 MOON ROOF LEAKS 68 OASIS CODES: 110000,190000, 202000, 203000, 205000, 206000 Windshield Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10040 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10041 Refer To Figures 1, 2, and 3 1. Remove A-pillar mouldings, rocker panel scuff plates, and cowl lower scuff plates. Refer to the appropriate Workshop Manual, Section 501-05. 2. Apply a water hose at the bottom center of the windshield and slowly move outboard at a rate of 305 mm (1 foot) per 15-20 seconds. Then move up one side, inboard along top of header to the center. Lift the moulding at top of windshield to allow water to pass through windshield moulding. NOTE A NARROW NYLON TIP ON THE END OF THE HOSE WILL ALLOW THE OPERATOR TO EASILY SLIDE THE TIP UNDER THE MOULDING AND SLOWLY MOVE IT ALONG THE INSIDE SURFACE. 3. To determine if water is entering, have an observer use a flashlight to watch for water as the hose is being moved. The observer should start looking at the dash back panel by pulling back the dash insulator pad above the water location. 4. If a leak is detected, document the location and path for future reference. 5. Fill any voids with pumpable Butyl Sealer. NOTE TO REPAIR WATER LEAKS FOUND AT THE BASE OF THE WINDSHIELD, THE LEAF SCREEN MUST FIRST BE REMOVED. Cowl Top Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10042 Refer To Figure 4 1. Remove the leaf screen by referring to the appropriate Workshop Manual, Section 501-02. 2. Spray water into cowl top-to-dash panel seam. Spray for up to 20 minutes. 3. Inspect the inner dash panel for water intrusion, starting at the bottom of the cowl area. 4. With the trim rocker cover and kick plate removed, pull back carpet and inspect for water. 5. If no water is found, look in the area of the cross car beam and/or lower windshield "VIN tag" area. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10043 6. Seal inner cowl with seam sealer. Cowl Side-to-Door Opening Panel Leaks Service Procedure Refer To Figure 5 1. Remove the left front tire. 2. Remove the inner fender splash shield from the left front fender. Refer to the appropriate Workshop Manual, Section 501-02, for details. 3. Remove the grille by referring to the Workshop Manual, Section 501-08. 4. Remove the left front fender by referring to the Workshop Manual, Section 501-02. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10044 5. Test with water. 6. Apply seam sealer along the interface between the cowl and the dash panel. This area can be reached through the access hole located near the top hinge for the front door. 7. Reassemble in reverse order. 8. Apply paint protection to fender bolts. Cowl Side-to-Dash Panel Leaks Service Procedure Refer To Figure 6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10045 1. Remove rocker cover and lower scuff panel by referring to the appropriate Workshop Manual, Section 501-05. 2. Inspect dash panel-to-cowl side inner sealer for skips and/or missing sealer. 3. Test with water at the top of the cowl/leaf screen area and inspect the vehicle for water entry. 4. Apply seam sealer along the interface between the cowl, dash, and floor panel. Moonroof Leaks Service Procedure Refer To Figure 7 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10046 1. Before beginning any diagnosis, contact the Webasto Tech Hotline at (800) 995-5911 Monday-Friday, 9AM-6PM EST. 2. Cycle moonroof to open position. 3. Check for proper drain tube action by pouring approximately 1.8L (6 oz) of water into trough at each side. 4. If tubes appear to be draining properly, remove the interior A-pillar trim and sun visors. Refer to the appropriate Workshop Manual, Section 501-05. 5. Pull down the headliner slightly and inspect moonroof drain tubes for kinks and/or twists. The drain tubes must be free from any bends or obstruction of water flow. 6. Straighten or cut drain tubes to proper length to allow for free draining. Grommets Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 10047 Refer To Figure 8 1. Check for missing or improperly seated grommets in the following areas: ^ Antenna grommet on passenger side cowl ^ Park brake cable grommet on driver side cowl ^ Overall instrument panel grommets 2. Reseat any loose grommets or replace any missing grommets. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10056 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10057 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10058 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 01-21-12 > Oct > 01 > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 01-21-12 > Oct > 01 > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10068 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 01-21-12 > Oct > 01 > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10069 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 01-21-12 > Oct > 01 > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10070 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 98-21-10 > Oct > 98 > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 98-21-10 > Oct > 98 > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10081 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 98-21-10 > Oct > 98 > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10082 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 98-21-10 > Oct > 98 > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10083 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 98-21-10 > Oct > 98 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 98-21-10 > Oct > 98 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10089 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 98-21-10 > Oct > 98 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10090 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 98-21-10 > Oct > 98 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10091 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > Page 10092 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10102 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10103 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10104 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10105 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10106 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10107 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10108 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10109 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10110 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10111 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10112 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10113 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10114 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10115 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10116 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10117 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10118 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10119 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10120 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10121 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10122 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10123 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10124 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10125 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10126 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10127 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10132 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10142 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10143 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10144 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10145 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10146 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10147 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10148 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10149 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10150 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10151 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10152 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10153 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10154 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10155 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10156 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10157 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10158 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10159 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10160 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10161 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10162 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10163 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10164 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10165 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10166 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10167 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10172 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams Speed Control Servo/Amplifier Assembly Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Speed Control Actuator <--> [Cruise Control Servo] > Component Information > Specifications Speed Control Actuator: Specifications Speed Control Servo Bracket Bolts ........................................................................................................................................... 7.6-10.4 N.m (5.6-7.7 Lb-Ft) Speed Control Servo Bracket Screws ............................................................................................................................................ 10-13 N.m (90-115 Lb-In) Accelerator Control Splash Shield Screws .................................................................................................................................... 3.1-4.3 N.m (28-38 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Speed Control Actuator <--> [Cruise Control Servo] > Component Information > Specifications > Page 10183 Speed Control Servo/Amplifier Assembly Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Speed Control Actuator <--> [Cruise Control Servo] > Component Information > Specifications > Page 10184 Speed Control Actuator: Service and Repair REMOVAL 1. Remove the speed control actuator cable cap from the speed control servo. 1 Push in the locking arm on the speed control actuator cable cap. 2 Rotate the speed control actuator cable cap counterclockwise and remove the speed control actuator cable cap from the speed control servo. 2. Disconnect the speed control actuator cable from the speed control servo. 1 Depress the spring retainer. 2 Slide the core wire end out of the speed control servo pulley. 3. Disconnect the speed control servo electrical connector. 4. Remove the speed control servo and bracket. 1 Remove the bolts. 2 Remove the speed control servo and bracket. NOTE: Do not remove the rubber grommets from the speed control servo bracket. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Speed Control Actuator <--> [Cruise Control Servo] > Component Information > Specifications > Page 10185 5. Remove the speed control servo bracket. 1 Remove the screws. 2 Remove the speed control servo bracket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The rubber grommets must be properly seated in the speed control servo bracket for proper noise and vibration isolation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Speed Control Actuator Cable <--> [Cruise Control Servo Cable] > Component Information > Specifications Speed Control Actuator Cable: Specifications Speed Control Actuator Cable to Accelerator Cable Bracket Bolt .................................................................................................................................................... 4.1-6.0 N.m (37-54 Lb-In) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Speed Control Actuator Cable <--> [Cruise Control Servo Cable] > Component Information > Specifications > Page 10189 Speed Control Actuator Cable: Adjustments 1. Remove the speed control actuator cable clip. 2. Adjust the speed control actuator cable. 1 Set the throttle body cam to the closed position. 2 Pull on the speed control actuator cable to remove any slack. 3 Back off the speed control actuator cable one notch. NOTE: The speed control actuator cable must NOT be pulled tight for proper operation. 3. Hold the (A) speed control actuator cable and insert the (B) speed control actuator cable clip securely. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Speed Control Actuator Cable <--> [Cruise Control Servo Cable] > Component Information > Specifications > Page 10190 Speed Control Actuator Cable: Service and Repair REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the screws. 2 Remove the accelerator control splash shield. 2. Remove the speed control actuator cable. - Lift the speed control actuator cable upward to remove. 3. Remove the speed control actuator cable to accelerator cable bracket bolt. 4. Remove the speed control actuator cable cap from the speed control servo. 1 Push in the locking arm on the speed control actuator cable cap. 2 Rotate the speed control actuator cable cap counterclockwise and remove the speed control actuator cable cap from the speed control servo. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Speed Control Actuator Cable <--> [Cruise Control Servo Cable] > Component Information > Specifications > Page 10191 5. Remove the speed control actuator cable. 1 Depress the spring retainer. 2 Slide the core wire end out of the speed control servo pulley and remove the speed control actuator cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 10205 Cruise Control Switch: Service and Repair REMOVAL 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 (B) remove the speed control actuator switch. 2 Disconnect the speed control actuator switch electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams Speed Control Servo/Amplifier Assembly Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10219 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10220 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10221 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10222 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10223 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10224 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10225 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10226 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10227 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10228 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10229 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10230 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10231 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10232 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10233 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10234 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10235 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10236 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10237 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10238 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10239 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10240 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10241 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10242 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10243 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10244 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10249 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10259 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10260 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10261 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10262 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10263 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10264 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10265 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10266 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10267 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10268 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10269 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10270 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10271 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10272 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10273 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10274 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10275 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10276 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10277 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10278 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10279 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10280 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10281 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10282 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10283 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10284 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10289 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 10307 Cruise Control Switch: Service and Repair REMOVAL 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 (B) remove the speed control actuator switch. 2 Disconnect the speed control actuator switch electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: Customer Interest Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 10317 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: All Technical Service Bulletins Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 10323 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10326 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10327 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10328 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10329 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10330 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10331 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10332 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10333 Audible Warning Device: Electrical Diagrams Warning Chime (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10334 Warning Chime (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 10335 Audible Warning Device: Description and Operation The Generic Electronic Module (GEM) controls the following warnings and chimes: ^ Driver safety belt not fastened warning (warning lamp and repetitive chime). ^ Key-in-ignition warning (repetitive chime). ^ Headlamp-on warning (repetitive chime). ^ Door ajar warning (warning lamp and single tone). ^ Low washer fluid warning (warning lamp and single tone). The safety belt warning chime warns that the safety belt is not fastened. The safety belt warning chime will sound when the driver safety belt is not fastened and the ignition switch is turned from the OFF/LOCK or ACC to the RUN or START position. The safety belt warning chime will stop sounding when the safety belt is fastened, when the ignition switch is switched from the RUN or START to the OFF/LOCK or ACC position, and when the chime has sounded for six seconds. The safety belt warning chime inputs are: ^ Ignition switch START position (battery potential when in START position). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 10336 ^ Ignition switch RUN position (battery potential on both the RUN and RUN/ACC inputs). ^ Driver safety belt switch (grounded when not fastened; open circuit when fastened). The safety belt warning lamp warns that the safety belt is not fastened. The safety belt warning lamp illuminates when it is grounded and turns off when the circuit is open. The safety belt warning lamp will be illuminated when the safety belt is not fastened and the ignition switch is turned from the OFF/LOCK or ACC to the RUN or START position. The safety belt warning lamp will turn off when the safety belt is fastened, the ignition switch is moved from the RUN or START to the OFF/LOCK or ACC position, or if the lamp is illuminated for 61 seconds. The safety belt warning lamp inputs are: ^ Ignition switch START position (battery potential when in START). ^ Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs). ^ Driver safety belt switch (grounded when not fastened; open circuit when fastened). The door ajar warning chime warns that a door is ajar. The door ajar warning chime is a single tone with a duration of one second. The chime will sound when the right front, right rear, left front, left rear, liftgate, or liftgate glass initially becomes ajar while the ignition switch is in the RUN position. The door ajar warning chime inputs are: ^ Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs). ^ Door open warning lamp switches (grounded when ajar; open circuit when closed). The door ajar warning lamp warns that a door is ajar. The door ajar warning lamp illuminates when it is grounded. The door ajar warning lamp will be illuminated when any door, the liftgate, or liftgate glass initially becomes ajar while the ignition switch is in the RUN or START position. The door ajar warning lamp will turn off when all doors, the liftgate glass and the liftgate are closed, and the ignition switch is turned to the OFF/LOCK or ACC position. The door ajar warning lamp inputs are: ^ Ignition switch START position (battery potential when in START). ^ Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs). ^ Door open warning lamp switches (grounded with door ajar; open circuit with door closed). The key-in-ignition warning chime warns that the key is still in the ignition when the driver door is ajar. The key-in-ignition warning chime will sound when the driver door is ajar, the ignition switch is in the OFF/LOCK or ACC position and the key is in the ignition. The key-in-ignition warning chime will stop sounding when the driver door is closed, the key is removed from the ignition, or if the ignition switch is moved to the RUN position. The key-in-ignition warning chime inputs are: ^ Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs). ^ Ignition switch ACC position (battery potential on RUN/ACC input only). ^ Key-in-ignition switch (grounded with key-in-ignition, open circuit with key-out). ^ LF door open warning lamp switch (open circuit with door closed; grounded with door ajar). The headlamp on warning chime warns that the headlamps are on when the driver door is ajar. The headlamps on warning chime will sound if the driver door is ajar, the headlamp switch is in the PARK or HEAD position, and the ignition switch state is in the OFF/LOCK position with the key out. The headlamp on warning chime will stop sounding when any one of the conditions above are removed. The headlamp on warning chime inputs are: ^ Ignition switch OFF/LOCK (open circuit on all ignition inputs). ^ Headlamp switch (battery potential when in PARK or HEAD position; open circuit when in OFF position). ^ LF door open warning lamp switch (open circuit with door closed; grounded with door ajar). ^ Key-in-ignition switch (grounded with key-in-ignition; open circuit with key-out). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Audible Warning Device: Initial Inspection and Diagnostic Overview 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical and electrical damage using the Visual Inspection Chart. VISUAL INSPECTION CHART Mechanical ^ Key-in-ignition warning switch ^ Door open warning lamp switch ^ Safety belt warning indicator switch Electrical ^ Fuse(s) ^ Damaged wiring harness ^ Loose or corroded connections ^ Circuitry 3. If the concern remains after the inspection, connect New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If NGS does not communicate with the vehicle: ^ Check that the program card is properly installed. ^ Check the connections to the vehicle. ^ Check the ignition switch position. 4. If NGS still does not communicate with the vehicle. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT 914, CKT 915 or CKT 70 = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test G. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to GEM Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10339 Audible Warning Device: Diagnostic Trouble Code Descriptions Part 1 Of 4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10340 Part 2 Of 4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10341 Part 3 Of 4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10342 Part 4 Of 4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10343 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10344 Audible Warning Device: Pinpoint Tests A: Safety Belt Warning Chime Doesn't Operate Correctly A1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10345 A2 - A3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10346 A4 - A6 B: The Key-In-Ignition Chime Is Inop (LF Door Only) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10347 B1 - B3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10348 B4 - B5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10349 B6 C1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10350 D1 - D3 E: Headlamp On Reminder Chime Not Operating Properly Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10351 E1 - E3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10352 E4 - E6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10353 E7 - E8 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10354 E9 F1 - F2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10355 F3 G: No Communication With the Module-GEM G1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10356 G2 - G3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10357 G4 - G5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10358 Audible Warning Device: Testing and Inspection Initial Inspection and Diagnostic Overview 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical and electrical damage using the Visual Inspection Chart. VISUAL INSPECTION CHART Mechanical ^ Key-in-ignition warning switch ^ Door open warning lamp switch ^ Safety belt warning indicator switch Electrical ^ Fuse(s) ^ Damaged wiring harness ^ Loose or corroded connections ^ Circuitry 3. If the concern remains after the inspection, connect New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If NGS does not communicate with the vehicle: ^ Check that the program card is properly installed. ^ Check the connections to the vehicle. ^ Check the ignition switch position. 4. If NGS still does not communicate with the vehicle. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT 914, CKT 915 or CKT 70 = ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test G. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to GEM Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Diagnostic Trouble Code Descriptions Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10359 Part 1 Of 4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10360 Part 2 Of 4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10361 Part 3 Of 4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10362 Part 4 Of 4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10363 A: Safety Belt Warning Chime Doesn't Operate Correctly Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10364 A1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10365 A2 - A3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10366 A4 - A6 B: The Key-In-Ignition Chime Is Inop (LF Door Only) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10367 B1 - B3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10368 B4 - B5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10369 B6 C1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10370 D1 - D3 E: Headlamp On Reminder Chime Not Operating Properly Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10371 E1 - E3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10372 E4 - E6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10373 E7 - E8 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10374 E9 F1 - F2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10375 F3 G: No Communication With the Module-GEM G1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10376 G2 - G3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10377 G4 - G5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10378 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10379 Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10380 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Testing and Inspection Brake Warning Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Testing and Inspection Charge Lamp/Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10391 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10392 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10393 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10394 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10395 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10396 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10397 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10398 Cigar Lighter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Directional Sensor > Component Information > Locations Directional Sensor: Locations Body View The Compass Sensor is located in the overhead console. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Directional Sensor > Component Information > Locations > Page 10403 Compass Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect the battery ground cable. WARNING: THE BACKUP POWER SUPPLY ENERGY MUST BE DEPLETED BEFORE ANY AIR BAG COMPONENT REPAIR IS PERFORMED. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the driver side air bag module from the vehicle. WARNING: PLACE THE AIR BAG MODULE ON A BENCH WITH THE TRIM COVER FACING UP TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 4. Connect the air bag simulator to the vehicle harness at the top of the steering column. 5. Remove the passenger side air bag module from the vehicle. WARNING: PLACE THE AIR BAG MODULE ON A BENCH WITH THE DEPLOYMENT DOOR FACING UP TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 6. Connect the air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Reactivation Procedure 1. Disconnect the battery ground cable. WARNING: THE AIR BAG SIMULATORS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. In stall the driver side air bag module. 5. Remove the air bag simulator from the vehicle harness connector at the passenger side air bag module. 6. Install the passenger side air bag module. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 8. Prove out the system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 10409 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Are both air bag sensors connected and mounted to the vehicle? [ ] 2. Is the three-way connector at the base of the steering column connected? [ ] 3. Are the air bag modules or air bag simulators connected? [ ] 4. Is the air bag diagnostic monitor connected? [ ] 5. Is the vehicle battery connected? [ ] Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations Dimmer Switch: Locations The panel dimmer switch is integrated into the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Page 10413 Dimmer Switch: Description and Operation The panel dimmer switch is integrated into the headlamp switch and controls the interior lamps by activating the interior lamp relay. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Testing and Inspection Door/Trunk Ajar Indicator/Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the electrical connector. 2 Rotate interior lamp switch counterclockwise to remove. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation Driver/Vehicle Information Display: Description and Operation NOTE: ^ The Distance To Empty (DTE) display may be inaccurate if the vehicle is started while parked on an incline. ^ Fuel fills of less than 22.7 liters (six gallons) may not be detected by the message center. The message center displays: ^ Compass direction. ^ DTE. ^ Average (AVG) fuel economy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 10423 ^ Instantaneous (INST) fuel economy. The message center inputs are: ^ Compass sensor module data (+) and (-). ^ VSS. ^ Fuel level sensor data. ^ Data Output Line (DOL) fuel flow data from the PCM. Average Fuel Economy-Resetting NOTE: Only the AVG fuel economy can be reset. DTE and INST displays cannot be reset. The average fuel economy display is resettable. To reset, the ignition switch must be in the RUN position (with or without the engine running) and the message center must be in the AVG fuel economy mode. Press and release the MODE and E/M buttons simultaneously. If the vehicle is parked while resetting, the AVG fuel economy will display 0.0 (English mode) or 99.9 (metric mode). If the vehicle is in motion, the AVG fuel economy will display the current INST fuel economy (English mode or metric mode). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the Visual Inspection Chart. VISUAL INSPECTION CHART Mechanical ^ Damaged overhead trip computer ^ Damaged Vehicle Speed Sensor (VSS) ^ Damaged compass sensor module or loose mounting ^ Damaged Powertrain Control Module (PCM) Electrical ^ Blown fuse: Fuse 2 (5A) - Fuse 6 (5A) ^ Damaged wiring harness ^ Loose or corroded connections 3. If the fault is not visually evident, perform the Message Center Self-Test. See: Component Tests and General Diagnostics/Message Center Self-Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10426 Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures NOTE: Always check ZONE and Calibration (CAL) adjustments before replacing the compass sensor module. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10427 Driver/Vehicle Information Display: Pinpoint Tests Test Note Do not proceed to the Pinpoint Tests until the Message Center Self-Test has been performed. A: The Compass Is Inaccurate A1 - A2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10428 A3 - A4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10429 A5 - A6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10430 A7 B: The Message Center Display Is Blank Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10431 B1 - B2 B3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10432 B4 - B5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10433 B6 C1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10434 D: Dist. To Empty/Av/Instant Fuel Economy Inop/Incorrect D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10435 D2 - D3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10436 D4 - D5 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10437 Driver/Vehicle Information Display: Component Tests and General Diagnostics Compass Zone Adjustment 1. The zone setting is factory pre-set to Zone 8. Check the Compass Calibration Zone map to verify the correct compass zone setting for your geographic location. 2. Insert an appropriate-diameter rod, preferably non-metallic, into the switch access hole underneath the compass module. Gently press the switch for one to two seconds until ZONE and the current zone setting are displayed. 3. Release the switch. 4. Press the switch repeatedly to cycle the display through all possible zone settings. Stop cycling when the correct zone setting for your location is displayed. 5. Release the switch to exit the zone setting mode. Message Center Self-Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10438 Message Center 1. The Message Center Self-Test can be entered by pressing the E/M and MODE buttons simultaneously while starting the vehicle. After entering the Message Center Self-Test release the E/M and MODE buttons. Advancing to a desired test is accomplished by pressing the MODE button. To abort the Message Center Self-Test, turn the ignition switch to the OFF position. NOTE: Vehicle doors must be closed and the engine must be running while in the Message Center Self-Test mode to receive accurate data. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10439 Part 1 Of 3 Part 2 Of 3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10440 Part 3 Of 3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Calibration Adjustment Driver/Vehicle Information Display: Service and Repair Calibration Adjustment 1. For optimum calibration, turn off all non-essential electrical accessories (rear window defrost, heater/air conditioning, map lamps, wipers, etc.) and make sure all doors are shut. 2. Drive to an open, level area away from large metallic objects or structures and high voltage lines. 3. Insert an appropriate-diameter rod, preferably non-metallic, into the switch access hole underneath the compass module. Press gently for two to four seconds until CAL and a direction are displayed. 4. Release the switch and drive slowly in a circle until CAL disappears from the display (about two to three circles). 5. The compass is now calibrated. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Calibration Adjustment > Page 10443 Driver/Vehicle Information Display: Service and Repair Compass Zone Adjustment 1. The zone setting is factory pre-set to Zone 8. Check the Compass Calibration Zone map to verify the correct compass zone setting for your geographic location. 2. Insert an appropriate-diameter rod, preferably non-metallic, into the switch access hole underneath the compass module. Gently press the switch for one to two seconds until ZONE and the current zone setting are displayed. 3. Release the switch. 4. Press the switch repeatedly to cycle the display through all possible zone settings. Stop cycling when the correct zone setting for your location is displayed. 5. Release the switch to exit the zone setting mode. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Calibration Adjustment > Page 10444 Driver/Vehicle Information Display: Service and Repair Message Center Assembly REMOVAL 1. Open the overhead sunglasses compartment and remove the screw. 2. Grasp the front of the overhead console and pull down to remove the console. 3. Disconnect the electrical connectors. 4. Remove the message center. 1 Depress the lock tab underneath the in-line electrical connector. 2 Remove the in-line connector. 3 Remove the screws. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Calibration Adjustment > Page 10445 4 Remove the message center. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Calibration Adjustment > Page 10446 Driver/Vehicle Information Display: Service and Repair Vehicle Demagnetizing CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a cloth over the vehicle's roof to protect the vehicle's surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. NOTE: ^ The demagnetizing process requires the use of a demagnetizing coil commonly used by television service technicians to demagnetize television tubes. ^ To demagnetize, use a constant circular motion over the vehicle's roof. Do not turn off the demagnetizer while sweeping the vehicle's roof to prevent remagnetizing ferrous materials contained in the vehicle. ^ During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite the handle) is closest to the vehicle's surface. 1. Demagnetize the front third of the vehicle's roof. 1 Turn on the demagnetizer at least 1 meter (3 ft) away from the vehicle. 2 Holding the demagnetizer no more than 2.5 cm (1 in) from the roof and starting on the passenger side, demagnetize the front third of the roof closest to the windshield using a constant circular motion. Keep the circle's radius within 30 cm (12 in) while sweeping across the entire surface of the roof closest to the windshield. Continue the circular motion four times. 3 After the fourth pass and without stopping, move the demagnetizer at least 1 meter (3 ft) away from the vehicle. 4 Turn the demagnetizer off. 2. 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. NOTE: The demagnetizer must be located over the outside of the windshield no greater than 2.5 cm (1 in). 3. Perform the Compass Zone Adjustment procedure. 4. Perform the Calibration Adjustment procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 10447 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Pinpoint Tests Fuel Gauge: Pinpoint Tests For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 10455 Fuel Gauge: Component Tests and General Diagnostics Preliminary Setup 1. Disconnect the fuel level sensor and pump C415. Connect one lead of Instrument Gauge System Tester to fuel level sensor and pump C415-8, circuit 29 (Y/W), and the other lead to ground. 2. Set Instrument Gauge System Tester to 22.4 ohms. Key ON. Wait one minute. The fuel gauge should indicate E (empty). Key OFF. 3. Set Instrument Gauge System Tester to 145 ohms. Key ON. Wait one minute. The fuel gauge should indicate F (full). Key OFF. Return to the pinpoint test. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect the battery ground cable. WARNING: THE BACKUP POWER SUPPLY ENERGY MUST BE DEPLETED BEFORE ANY AIR BAG COMPONENT REPAIR IS PERFORMED. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the driver side air bag module from the vehicle. WARNING: PLACE THE AIR BAG MODULE ON A BENCH WITH THE TRIM COVER FACING UP TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 4. Connect the air bag simulator to the vehicle harness at the top of the steering column. 5. Remove the passenger side air bag module from the vehicle. WARNING: PLACE THE AIR BAG MODULE ON A BENCH WITH THE DEPLOYMENT DOOR FACING UP TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 6. Connect the air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Reactivation Procedure 1. Disconnect the battery ground cable. WARNING: THE AIR BAG SIMULATORS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. In stall the driver side air bag module. 5. Remove the air bag simulator from the vehicle harness connector at the passenger side air bag module. 6. Install the passenger side air bag module. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 8. Prove out the system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 10461 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Are both air bag sensors connected and mounted to the vehicle? [ ] 2. Is the three-way connector at the base of the steering column connected? [ ] 3. Are the air bag modules or air bag simulators connected? [ ] 4. Is the air bag diagnostic monitor connected? [ ] 5. Is the vehicle battery connected? [ ] Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the (A) ignition switch lock cylinder release tab while pulling out the (B) ignition switch lock cylinder. 3. Remove the key in ignition warning switch. 1 Pry the clip downward. 2 Release the key-in-ignition warning switch from the rear of the ignition switch lock cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Service and Repair > Page 10465 INSTALLATION 1. To install, reverse the removal procedure. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Testing and Inspection Low Fuel Lamp/Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Testing and Inspection Odometer: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 NOTE : The RESET procedure is found ONLY in the Owners Manual. For most Ford vehicles, the RESET procedure mainly includes just pressing the RESET button for five(5) seconds but it is recommended that the Owners Manual is consulted first. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions Outside Temperature Display: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10485 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10486 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10487 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10488 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10489 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10490 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10491 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10492 Outside Temperature Display: Electrical Diagrams Overhead Console (Part 1 Of 2 ) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10493 Overhead Console (Part 2 Of 2 ) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) AND TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The Transmission Control Switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the Transmission Control Indicator Lamp (TCIL) when the switch is off. The TCIL indicates overdrive cancel mode activated (lamp on) and Electronic Pressure Control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Overdrive Indicator Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the transmission external control. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart: 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10499 Overdrive Indicator Lamp: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10500 Overdrive Indicator Lamp: Pinpoint Tests Test D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10501 Test D1 - D2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10502 Test D3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Testing and Inspection Speedometer Module: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Testing and Inspection Seat Belt Reminder Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations Dimmer Switch: Locations The panel dimmer switch is integrated into the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Page 10514 Dimmer Switch: Description and Operation The panel dimmer switch is integrated into the headlamp switch and controls the interior lamps by activating the interior lamp relay. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Directional Sensor > Component Information > Locations Directional Sensor: Locations Body View The Compass Sensor is located in the overhead console. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Directional Sensor > Component Information > Locations > Page 10518 Compass Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the electrical connector. 2 Rotate interior lamp switch counterclockwise to remove. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the (A) ignition switch lock cylinder release tab while pulling out the (B) ignition switch lock cylinder. 3. Remove the key in ignition warning switch. 1 Pry the clip downward. 2 Release the key-in-ignition warning switch from the rear of the ignition switch lock cylinder. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Service and Repair > Page 10525 INSTALLATION 1. To install, reverse the removal procedure. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the (D) position. - Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise ((D) position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumb wheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Testing and Inspection Speedometer Module: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Testing and Inspection Tachometer: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Service and Repair Temperature Sensor (Gauge): Service and Repair REMOVAL 1. Partially drain the engine cooling system. 2. Remove the water temperature indicator sender unit. 1 Disconnect the electrical connector. 2 Remove the water temperature indicator sender unit. INSTALLATION 1. Install the water temperature indicator sender unit. 1 Install the water temperature indicator sender unit. 2 Connect the electrical connector. 2. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Testing and Inspection Transmission Shift Position Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Testing and Inspection Volt Meter Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Transmission View The Digital Transmission Range Sensor is located at the left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 10555 Backup Lamp Switch: Diagrams Digital Transmission Range Sensor Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 10556 Backup Lamp Switch: Service and Repair The backup lamp switch is integral to the Digital Transmission Range (DTR)sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 10565 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 10571 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Page 10572 Brake Lamp: Specifications Rear Lamp Screws .............................................................................................................................. ...................................... 2.8-4.2 Nm (24.7-37.1 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10575 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10576 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10577 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10578 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10579 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10580 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10581 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10582 Brake Lamp: Electrical Diagrams Turn/Stop/Hazard Lamps (Part 1 Of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10583 Turn/Stop/Hazard Lamps (Part 2 Of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10584 Turn/Stop/Hazard Lamps (Part 3 Of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Page 10585 Brake Lamp: Description and Operation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Page 10586 The Brake Pedal Position (BPP) switch controls the brake lamps and rear hi-mount lamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis Brake Lamp: Flow of Diagnosis 1. Verify the customer concern by operating the stoplamps. 2. Visually inspect for obvious signs of mechanical and electrical damage: VISUAL INSPECTION CHART Mechanical ^ Damaged Brake Pedal Position (BPP) switch Electrical ^ Blown fuse ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged stoplamp bulb 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10589 Brake Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the stoplamps. 2. Visually inspect for obvious signs of mechanical and electrical damage: VISUAL INSPECTION CHART Mechanical ^ Damaged Brake Pedal Position (BPP) switch Electrical ^ Blown fuse ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged stoplamp bulb 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10590 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10591 Brake Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10592 L1 - L2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10593 L3 - L4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10594 M1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10595 M2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10596 N1 - N3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 10597 Brake Lamp: Service and Repair REMOVAL 1. Raise the liftgate and remove the rear lamp screws. 2. Remove the rear lamp assembly. 1 Pull the rear lamp assembly outward. 2 Disconnect the electrical connector and remove the rear lamp assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 10598 73 Digital Multimeter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation Brake Light Switch: Description and Operation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 10602 The Brake Pedal Position (BPP) switch controls the brake lamps and rear hi-mount lamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 10603 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Brake Pedal Position (BPP) switch electrical connector. 3. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the (A) BPP switch from the (B) brake master cylinder push rod. 3 Remove the brake master cylinder push rod spacer. 4 Remove the brake master cylinder push rod bushing. INSTALLATION 1. To install, reverse the removal procedure. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Center Mounted Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 10612 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling Center Mounted Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling > Page 10618 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Page 10619 Center Mounted Brake Lamp: Specifications Rear Hi-Mount Lamp Screws ................................................................................................................................................... 1.2-1.8 Nm (10.6-15.9 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Page 10620 Center Mounted Brake Lamp: Description and Operation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Page 10621 The Brake Pedal Position (BPP) switch controls the brake lamps and rear hi-mount lamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations > Interior Lamp Relay Courtesy Lamp Relay: Locations Interior Lamp Relay Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations > Interior Lamp Relay > Page 10627 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Interior Lamp Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations > Interior Lamp Relay > Page 10628 Courtesy Lamp Relay: Locations Running Board Lamp Relay Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations > Interior Lamp Relay > Page 10629 RPO Relay Block The Running Board Relay is located in the regular production option relay block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Service and Repair > Door Lamp Door Lamp: Service and Repair Door Lamp REMOVAL 1. Remove the door trim panel. 2. Remove the interior lamp. ^ Pry the interior lamp from the trim panel. ^ Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Service and Repair > Door Lamp > Page 10634 Door Lamp: Service and Repair Door Lamp Bulb REMOVAL 1. Remove the door trim panel. 2. Rotate the courtesy lamp bulb socket counterclockwise and remove. 3. Pull outward to remove the courtesy lamp bulb. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the electrical connector. 2 Rotate interior lamp switch counterclockwise to remove. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications Daytime Running Lamp Control Unit: Specifications Daytime Running Lamps Control Module Bolt ............................................................................................................................... 2.5-3.1 Nm (22-28 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10642 Daytime Running Lamp Control Unit: Locations Engine View The Daytime Running Lamps (DRL) Control Module is located on the radiator support. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10643 Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10644 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Remove the daytime running lamps control module from the radiator support. 1 Remove the bolt. 2 Disconnect the electrical connector. 3 Remove the daytime running lamps control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations Dimmer Switch: Locations The panel dimmer switch is integrated into the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Page 10648 Dimmer Switch: Description and Operation The panel dimmer switch is integrated into the headlamp switch and controls the interior lamps by activating the interior lamp relay. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Locations Battery Saver Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Locations > Page 10652 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Battery Saver Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Locations > Page 10653 Battery Saver Relay: Description and Operation The following components are controlled by the battery saver relay: - Interior lamps - Under hood lamp - Glove compartment lamp - Interior lamp relay - Accessory delay relay - Illuminated vanity mirrors (Navigator only) The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake mode, or in the sleep mode, (relay coil is de-energized). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the electrical connector. 2 Rotate interior lamp switch counterclockwise to remove. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Locations Exterior Lighting Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Locations > Page 10661 RPO Relay Block The Park Lamp Relay is located in the Regular Production Option relay block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 10666 Power Distribution Relay Box The Fog Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Description and Operation Fog/Driving Lamp Switch: Description and Operation The headlamp switch is a four position switch that controls the headlamps, exterior lamps, panel lamps, and, if equipped, the fog lamps and autolamp system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Description and Operation > Page 10670 Fog/Driving Lamp Switch: Service and Repair The fog lamp switch is integral to the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 10675 Blower/Flasher Relay Block The Flasher Relay is located in the blower/flasher relay block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Multi_function Switch Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 10679 Hazard Warning Switch: Description and Operation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 10680 The multi-function switch controls the turn signals, high beams, and hazard lamps. The Brake Pedal Position (BPP) switch controls the brake lamps and rear hi-mount lamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis Hazard Warning Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10683 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10684 Hazard Warning Switch: Pinpoint Tests A1 - A2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10685 A3 - A4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10686 B1 - B2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10687 C1 D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10688 Hazard Warning Switch: Component Tests and General Diagnostics Multi-Function Switch Component Test Multi-Function Switch - Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10689 Multi-Function Switch - Terminals Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10690 Multi-Function Switch - schematic - Dimmer,Flash To Pass,Turn/Hazard Portion Of Multi-Function Switch Multi-Function Switch Electrical Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10691 1. Measure the resistance between the multi-function switch terminals. 2. If the resistances are as specified, multi-function switch is OK. RETURN the multi-function switch to the vehicle. TEST the system for normal operation. If the resistances are not as specified. REPLACE the multi-function switch. TEST the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Technician Safety Information Headlamp Bulb: Technician Safety Information WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Technician Safety Information > Page 10697 Headlamp Bulb: Vehicle Damage Warnings NOTE: The headlamp bulb should not be removed from the headlamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamps with the bulb removed from the headlamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Page 10698 Headlamp Bulb: Service and Repair REMOVAL WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: The headlamp bulb should not be removed from the headlamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamps with the bulb removed from the headlamp. 1. Remove the headlamp assembly. 2. Rotate the headlamp bulb retainer counterclockwise and remove. 3. Remove the headlamp bulb by pulling it straight out with a gentle up-and-down rocking motion. INSTALLATION WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: ^ The headlamp bulb should not be removed from the headlamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamps with the bulb removed from the headlamp. ^ Be sure the headlamp assembly is positioned correctly with the alignment pins inserted into the proper holes and onto the ribs of the reinforcement. 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Locations Headlamp Control Module: Locations Instrument Panel View The Autolamp Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Locations > Page 10702 Autolamp Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 10706 Headlamp Dimmer Switch: Diagrams Multi_function Switch Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 10707 Headlamp Dimmer Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. The integrated multi-function switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer, rear wiper/washer and hazard warning. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Headlamp Dimmer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10710 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10711 Headlamp Dimmer Switch: Pinpoint Tests A1 - A2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10712 A3 - A4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10713 B1 - B2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10714 C1 D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10715 Headlamp Dimmer Switch: Component Tests and General Diagnostics Multi-Function Switch Component Test Multi-Function Switch - Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10716 Multi-Function Switch - Terminals Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10717 Multi-Function Switch - schematic - Dimmer,Flash To Pass,Turn/Hazard Portion Of Multi-Function Switch Multi-Function Switch Electrical Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10718 1. Measure the resistance between the multi-function switch terminals. 2. If the resistances are as specified, multi-function switch is OK. RETURN the multi-function switch to the vehicle. TEST the system for normal operation. If the resistances are not as specified. REPLACE the multi-function switch. TEST the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 10719 Headlamp Dimmer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Release the four clips and remove the steering column opening cover. NOTE: Move gear selector to lowest position to access steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 10720 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Service Precautions > Technician Safety Information Headlamp Lens: Technician Safety Information WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Service Precautions > Technician Safety Information > Page 10725 Headlamp Lens: Vehicle Damage Warnings NOTE: The headlamp bulb should not be removed from the headlamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamps with the bulb removed from the headlamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Service Precautions > Page 10726 Headlamp Lens: Adjustments HEADLAMP ADJUSTMENT 1. Before starting headlamp assembly adjustment, check the following: ^ Tire inflation. ^ No other load is in the truck other than a half tank of gas. ^ Headlamps are clean. ^ Proper headlamp operation. ^ Vehicle is on level ground. 2. Aim the headlamps. ^ Use Headlamp Aimer Kit to adjust the headlamps. Turn the (A) adjuster to adjust the headlamp up or down. Turn the (B) adjuster to adjust the headlamp left or right. 3. Adjust the headlamps to specifications, located in the lower right corner of each headlamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Service Precautions > Page 10727 Headlamp Lens: Service and Repair REMOVAL WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: The headlamp bulb should not be removed from the headlamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamps with the bulb removed from the headlamp. 1. Raise and support the hood. 2. Disconnect the battery ground cable. 3. Remove the headlamp assembly. 1 Raise the headlamp retainers by pushing rearward and pulling up. 2 Disconnect the headlamp electrical connector. 3 Remove the headlamp assembly. INSTALLATION NOTE: ^ Be sure the headlamp assembly is positioned correctly with the alignment pins inserted into the proper holes and onto the ribs of the reinforcement. ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Service Precautions > Page 10728 1. To install, reverse the removal procedure. ^ Adjust the headlamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 10732 RPO Relay Block The Headlamp Relay is located in Regular Production Option relay block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Main Light Switch (C244) Main Light Switch (C245) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10736 Main Light Switch (C246) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10737 Headlamp Switch: Description and Operation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10738 The headlamp switch is a four position switch that controls the headlamps, exterior lamps, panel lamps, and, if equipped, the fog lamps and autolamp system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10739 Headlamp Switch: Testing and Inspection Main Light Switch -Component Testing Procedure (Part 1 Of 2) Main Light Switch - Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10740 Main Light Switch - Terminal Location Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10741 Main Light Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Autolamp Time Delay Switch Headlamp Switch: Service and Repair Autolamp Time Delay Switch The autolamp time delay switch is integral to the headlamp switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Autolamp Time Delay Switch > Page 10744 Headlamp Switch: Service and Repair Headlamp Switch REMOVAL 1. Disconnect the battery ground cable. 2. Turn the headlamp switch knob to the headlamp position and pull the knob. 3. Insert a thin tool to release the headlamp switch knob and remove. 4. Turn the headlamp switch knob 180 degrees and install. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Autolamp Time Delay Switch > Page 10745 5. Turn counterclockwise until the back of the headlamp switch knob is in the OFF position. 6. Turn the headlamp switch knob fully clockwise. 7. Remove the headlamp switch. 1 Pull the headlamp switch from the instrument panel. 2 Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Testing and Inspection Hi-Beam Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 10753 Power Distribution Box The Horn Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 10754 Horn Relay: Testing and Inspection 1. Measure the resistance between relay terminal 85 and all other terminals. If any resistance is 5 ohms or less, replace the relay. Otherwise, continue with the test. 2. Use jumper wires to apply battery voltage to terminals 30 and 85. Measure voltage at terminal 87A. If voltage is less than 10 volts, replace the relay. Otherwise, continue with the test. 3. Use a jumper wire to apply ground to terminal 86. Measure the voltage at terminal 87. If the voltage is less than 10 volts, replace the relay. Otherwise, return to the pinpoint tests. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Testing and Inspection Horn Switch: Testing and Inspection The horn switch is integral to the driver side air bag module. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations Interior Lighting Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 10761 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Interior Lamp Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 10762 Interior Lighting Relay: Description and Operation The GEM controls the interior lamps illuminated entry function by activating the interior lamp relay. The relay is activated by applying ground to the relay coil through C267-15, and is deactivated by removing the ground signal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis License Plate Lamp: Flow of Diagnosis 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage: VISUAL INSPECTION CHART Mechanical ^ Damaged multi-function switch ^ Damaged headlamp switch Electrical ^ Blown fuse ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10767 License Plate Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage: VISUAL INSPECTION CHART Mechanical ^ Damaged multi-function switch ^ Damaged headlamp switch Electrical ^ Blown fuse ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10768 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10769 License Plate Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10770 T1 - T2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10771 T3 - T4 U The Autolamps Operate, But Park, Rear or License Inop Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10772 U1 - U2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10773 U3 - U4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10774 U5 - U6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10775 V1 - V2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10776 W1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10777 W2 - W3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10778 License Plate Lamp: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage: VISUAL INSPECTION CHART Mechanical ^ Damaged multi-function switch ^ Damaged headlamp switch Electrical ^ Blown fuse ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage: VISUAL INSPECTION CHART Mechanical ^ Damaged multi-function switch ^ Damaged headlamp switch Electrical ^ Blown fuse ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Icons Used With Pinpoint Tests Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10779 Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10780 T1 - T2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10781 T3 - T4 U The Autolamps Operate, But Park, Rear or License Inop Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10782 U1 - U2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10783 U3 - U4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10784 U5 - U6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10785 V1 - V2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10786 W1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10787 W2 - W3 Component Tests and General Diagnostics Terminals Relay Component Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10788 Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Micro ISO Relay Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Set 73 Digital Multimeter in volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect the third jumper wire to terminal 2 and ground the jumper wire to chassis ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. 73 Digital Multimeter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair Map Light Bulb: Service and Repair REMOVAL 1. Remove the map lamp assembly. 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 (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis Parking Lamp: Flow of Diagnosis 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage: VISUAL INSPECTION CHART Mechanical ^ Damaged multi-function switch ^ Damaged headlamp switch Electrical ^ Blown fuse ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10797 Parking Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage: VISUAL INSPECTION CHART Mechanical ^ Damaged multi-function switch ^ Damaged headlamp switch Electrical ^ Blown fuse ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10798 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10799 Parking Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10800 T1 - T2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10801 T3 - T4 U The Autolamps Operate, But Park, Rear or License Inop Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10802 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10803 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10804 U5 - U6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10805 V1 - V2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10806 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10807 W2 - W3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10808 Parking Lamp: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage: VISUAL INSPECTION CHART Mechanical ^ Damaged multi-function switch ^ Damaged headlamp switch Electrical ^ Blown fuse ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage: VISUAL INSPECTION CHART Mechanical ^ Damaged multi-function switch ^ Damaged headlamp switch Electrical ^ Blown fuse ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Icons Used With Pinpoint Tests Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10809 Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10810 T1 - T2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10811 T3 - T4 U The Autolamps Operate, But Park, Rear or License Inop Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10812 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10813 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10814 U5 - U6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10815 V1 - V2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10816 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10817 W2 - W3 Component Tests and General Diagnostics Terminals Relay Component Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10818 Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Micro ISO Relay Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Set 73 Digital Multimeter in volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect the third jumper wire to terminal 2 and ground the jumper wire to chassis ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. 73 Digital Multimeter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Locations Battery Saver Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Locations > Page 10823 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Battery Saver Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Locations > Page 10824 Battery Saver Relay: Description and Operation The following components are controlled by the battery saver relay: - Interior lamps - Under hood lamp - Glove compartment lamp - Interior lamp relay - Accessory delay relay - Illuminated vanity mirrors (Navigator only) The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake mode, or in the sleep mode, (relay coil is de-energized). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Interior Lamp Relay Courtesy Lamp Relay: Locations Interior Lamp Relay Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Interior Lamp Relay > Page 10829 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Interior Lamp Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Interior Lamp Relay > Page 10830 Courtesy Lamp Relay: Locations Running Board Lamp Relay Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Interior Lamp Relay > Page 10831 RPO Relay Block The Running Board Relay is located in the regular production option relay block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications Daytime Running Lamp Control Unit: Specifications Daytime Running Lamps Control Module Bolt ............................................................................................................................... 2.5-3.1 Nm (22-28 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10835 Daytime Running Lamp Control Unit: Locations Engine View The Daytime Running Lamps (DRL) Control Module is located on the radiator support. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10836 Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10837 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Remove the daytime running lamps control module from the radiator support. 1 Remove the bolt. 2 Disconnect the electrical connector. 3 Remove the daytime running lamps control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Locations Exterior Lighting Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Locations > Page 10842 RPO Relay Block The Park Lamp Relay is located in the Regular Production Option relay block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 10846 Power Distribution Relay Box The Fog Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Locations Headlamp Control Module: Locations Instrument Panel View The Autolamp Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Locations > Page 10850 Autolamp Module Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 10854 RPO Relay Block The Headlamp Relay is located in Regular Production Option relay block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 10858 Power Distribution Box The Horn Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 10859 Horn Relay: Testing and Inspection 1. Measure the resistance between relay terminal 85 and all other terminals. If any resistance is 5 ohms or less, replace the relay. Otherwise, continue with the test. 2. Use jumper wires to apply battery voltage to terminals 30 and 85. Measure voltage at terminal 87A. If voltage is less than 10 volts, replace the relay. Otherwise, continue with the test. 3. Use a jumper wire to apply ground to terminal 86. Measure the voltage at terminal 87. If the voltage is less than 10 volts, replace the relay. Otherwise, return to the pinpoint tests. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations Interior Lighting Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 10863 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Interior Lamp Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 10864 Interior Lighting Relay: Description and Operation The GEM controls the interior lamps illuminated entry function by activating the interior lamp relay. The relay is activated by applying ground to the relay coil through C267-15, and is deactivated by removing the ground signal. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay Trailer Lighting Relay: Locations Trailer Tow Backup Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 10869 The Trailer Tow Backup Lamp Relay is located in the Power Distribution Box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 10870 Trailer Lighting Relay: Locations Trailer Tow Battery Charge Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 10871 The Trailer Tow Backup Lamp Relay is located in the Power Distribution Box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 10872 Trailer Lighting Relay: Locations Trailer Tow Left Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 10873 The Trailer Tow Backup Lamp Relay is located in the Power Distribution Box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 10874 Trailer Lighting Relay: Locations Trailer Tow Right Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 10875 The Trailer Tow Backup Lamp Relay is located in the Power Distribution Box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Transmission View The Digital Transmission Range Sensor is located at the left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 10880 Backup Lamp Switch: Diagrams Digital Transmission Range Sensor Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 10881 Backup Lamp Switch: Service and Repair The backup lamp switch is integral to the Digital Transmission Range (DTR)sensor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation Brake Light Switch: Description and Operation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 10885 The Brake Pedal Position (BPP) switch controls the brake lamps and rear hi-mount lamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 10886 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Brake Pedal Position (BPP) switch electrical connector. 3. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the (A) BPP switch from the (B) brake master cylinder push rod. 3 Remove the brake master cylinder push rod spacer. 4 Remove the brake master cylinder push rod bushing. INSTALLATION 1. To install, reverse the removal procedure. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement Technical Service Bulletin # 99B02 Date: 990301 Campaign - Multifunction Switch Replacement 99B02 OWNER NOTIFICATION PROGRAM Certain 1997-98 Expedition and 1998 Navigator Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ All Dealer Letter: Lincoln Commitment Special Handling Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 10895 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 10896 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles that are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS PREPARATION See Sections 5 & 6 of the ACESII manual for detailed instructions. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code 99B02 Misc. Expense REFUND Misc. Expense ADMIN. Misc. Expense 0.2 Hr. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 10897 LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channel as noted. DEALER PRICE For latest prices, check or call your: -- Order Processing Center -- DOES II -- Updated Price Book EXCESS STOCK RETURN Excess stock return for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION -- Enter using DWE -- Use code information shown below: Program Code - 99B02 Labor Operation - See Above See Sections 5 & 6 of the ACESII manual for detailed instructions. To claim for the "Lincoln Commitment Special Handling", follow the instructions in Attachment IV. Attachment III - Technical Information TECHNICAL INSTRUCTIONS Please refer to Service Manual procedures: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 10898 ^ Group 2: Chassis ^ Section 211-05: Steering Column Switches ^ Removal and Installation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 10899 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 10900 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 10901 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement Technical Service Bulletin # 99B02 Date: 990301 Campaign - Multifunction Switch Replacement 99B02 OWNER NOTIFICATION PROGRAM Certain 1997-98 Expedition and 1998 Navigator Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ All Dealer Letter: Lincoln Commitment Special Handling Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 10907 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 10908 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles that are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS PREPARATION See Sections 5 & 6 of the ACESII manual for detailed instructions. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code 99B02 Misc. Expense REFUND Misc. Expense ADMIN. Misc. Expense 0.2 Hr. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 10909 LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channel as noted. DEALER PRICE For latest prices, check or call your: -- Order Processing Center -- DOES II -- Updated Price Book EXCESS STOCK RETURN Excess stock return for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION -- Enter using DWE -- Use code information shown below: Program Code - 99B02 Labor Operation - See Above See Sections 5 & 6 of the ACESII manual for detailed instructions. To claim for the "Lincoln Commitment Special Handling", follow the instructions in Attachment IV. Attachment III - Technical Information TECHNICAL INSTRUCTIONS Please refer to Service Manual procedures: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 10910 ^ Group 2: Chassis ^ Section 211-05: Steering Column Switches ^ Removal and Installation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 10911 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 10912 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 10913 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the electrical connector. 2 Rotate interior lamp switch counterclockwise to remove. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation Fog/Driving Lamp Switch: Description and Operation The headlamp switch is a four position switch that controls the headlamps, exterior lamps, panel lamps, and, if equipped, the fog lamps and autolamp system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Page 10920 Fog/Driving Lamp Switch: Service and Repair The fog lamp switch is integral to the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Multi_function Switch Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 10924 Hazard Warning Switch: Description and Operation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 10925 The multi-function switch controls the turn signals, high beams, and hazard lamps. The Brake Pedal Position (BPP) switch controls the brake lamps and rear hi-mount lamp. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis Hazard Warning Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10928 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10929 Hazard Warning Switch: Pinpoint Tests A1 - A2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10930 A3 - A4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10931 B1 - B2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10932 C1 D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10933 Hazard Warning Switch: Component Tests and General Diagnostics Multi-Function Switch Component Test Multi-Function Switch - Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10934 Multi-Function Switch - Terminals Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10935 Multi-Function Switch - schematic - Dimmer,Flash To Pass,Turn/Hazard Portion Of Multi-Function Switch Multi-Function Switch Electrical Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10936 1. Measure the resistance between the multi-function switch terminals. 2. If the resistances are as specified, multi-function switch is OK. RETURN the multi-function switch to the vehicle. TEST the system for normal operation. If the resistances are not as specified. REPLACE the multi-function switch. TEST the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 10940 Headlamp Dimmer Switch: Diagrams Multi_function Switch Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 10941 Headlamp Dimmer Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. The integrated multi-function switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer, rear wiper/washer and hazard warning. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Headlamp Dimmer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10944 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10945 Headlamp Dimmer Switch: Pinpoint Tests A1 - A2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10946 A3 - A4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10947 B1 - B2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10948 C1 D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10949 Headlamp Dimmer Switch: Component Tests and General Diagnostics Multi-Function Switch Component Test Multi-Function Switch - Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10950 Multi-Function Switch - Terminals Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10951 Multi-Function Switch - schematic - Dimmer,Flash To Pass,Turn/Hazard Portion Of Multi-Function Switch Multi-Function Switch Electrical Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10952 1. Measure the resistance between the multi-function switch terminals. 2. If the resistances are as specified, multi-function switch is OK. RETURN the multi-function switch to the vehicle. TEST the system for normal operation. If the resistances are not as specified. REPLACE the multi-function switch. TEST the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 10953 Headlamp Dimmer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Release the four clips and remove the steering column opening cover. NOTE: Move gear selector to lowest position to access steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 10954 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Main Light Switch (C244) Main Light Switch (C245) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10958 Main Light Switch (C246) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10959 Headlamp Switch: Description and Operation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10960 The headlamp switch is a four position switch that controls the headlamps, exterior lamps, panel lamps, and, if equipped, the fog lamps and autolamp system. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10961 Headlamp Switch: Testing and Inspection Main Light Switch -Component Testing Procedure (Part 1 Of 2) Main Light Switch - Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10962 Main Light Switch - Terminal Location Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10963 Main Light Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Autolamp Time Delay Switch Headlamp Switch: Service and Repair Autolamp Time Delay Switch The autolamp time delay switch is integral to the headlamp switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Autolamp Time Delay Switch > Page 10966 Headlamp Switch: Service and Repair Headlamp Switch REMOVAL 1. Disconnect the battery ground cable. 2. Turn the headlamp switch knob to the headlamp position and pull the knob. 3. Insert a thin tool to release the headlamp switch knob and remove. 4. Turn the headlamp switch knob 180 degrees and install. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Autolamp Time Delay Switch > Page 10967 5. Turn counterclockwise until the back of the headlamp switch knob is in the OFF position. 6. Turn the headlamp switch knob fully clockwise. 7. Remove the headlamp switch. 1 Pull the headlamp switch from the instrument panel. 2 Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Testing and Inspection Horn Switch: Testing and Inspection The horn switch is integral to the driver side air bag module. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the electrical connector. 2 Rotate interior lamp switch counterclockwise to remove. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 10977 Turn Signal Switch: Diagrams Multi_function Switch Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 10978 Turn Signal Switch: Description and Operation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 10979 The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. The integrated multi-function switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer, rear wiper/washer and hazard warning. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis Turn Signal Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10982 Turn Signal Switch: Diagnostic Trouble Code Descriptions Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10983 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10984 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10985 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10986 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10987 Turn Signal Switch: Component Tests and General Diagnostics Multi-Function Switch Electrical Test 1. Measure the resistance between the multi-function switch terminals. 2. If the resistances are as specified, multi-function switch is OK. RETURN the multi-function switch to the vehicle. TEST the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10988 If the resistances are not as specified. REPLACE the multi-function switch. TEST the system for normal operation. Multi-Function Switch Component Test Multi-Function Switch - Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10989 Multi-Function Switch - Terminals Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10990 Multi-Function Switch - schematic - Dimmer,Flash To Pass,Turn/Hazard Portion Of Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10991 Turn Signal Switch: Pinout Values and Diagnostic Parameters Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10992 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 10993 Turn Signal Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Release the four clips and remove the steering column opening cover. NOTE: Move gear selector to lowest position to access steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 10994 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Specifications Tail Lamp: Specifications Liftgate Lamp Nuts .............................................................................................................................. ..................................... 7.8-4.2 Nm (24.7-37.1 in lb) Rear Lamp Screws ........................................... ......................................................................................................................... 2.8-4.2 Nm (24.7-37.1 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis Tail Lamp: Flow of Diagnosis 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage: VISUAL INSPECTION CHART Mechanical ^ Damaged multi-function switch ^ Damaged headlamp switch Electrical ^ Blown fuse ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11000 Tail Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage: VISUAL INSPECTION CHART Mechanical ^ Damaged multi-function switch ^ Damaged headlamp switch Electrical ^ Blown fuse ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11001 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11002 Tail Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11003 T1 - T2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11004 T3 - T4 U Autolamps Operate, But Park Rear or License Lamps Inop Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11005 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11006 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11007 U5 - U6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11008 V1 - V2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11009 W1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11010 W2 - W3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11011 Tail Lamp: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage: VISUAL INSPECTION CHART Mechanical ^ Damaged multi-function switch ^ Damaged headlamp switch Electrical ^ Blown fuse ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage: VISUAL INSPECTION CHART Mechanical ^ Damaged multi-function switch ^ Damaged headlamp switch Electrical ^ Blown fuse ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Icons Used With Pinpoint Tests Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11012 Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11013 T1 - T2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11014 T3 - T4 U Autolamps Operate, But Park Rear or License Lamps Inop Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11015 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11016 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11017 U5 - U6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11018 V1 - V2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11019 W1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11020 W2 - W3 Component Tests and General Diagnostics Terminals Relay Component Test Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11021 Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Micro ISO Relay Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Set 73 Digital Multimeter in volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect the third jumper wire to terminal 2 and ground the jumper wire to chassis ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. 73 Digital Multimeter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Page 11022 Tail Lamp: Service and Repair REMOVAL 1. Raise the liftgate and remove the rear lamp screws. 2. Remove the rear lamp assembly. 1 Pull the rear lamp assembly outward. 2 Disconnect the electrical connector and remove the rear lamp assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11027 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11028 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11029 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11030 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11031 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11032 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11033 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11034 Trailer Lamps: Electrical Diagrams Trailer/Camper Adapter (Part 1 Of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11035 Trailer/Camper Adapter (Part 2 Of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11036 Trailer/Camper Adapter (Part 3 Of 3) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis Trailer Lamps: Flow of Diagnosis 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Blown fuse(s) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11039 Trailer Lamps: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Blown fuse(s) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11040 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11041 Trailer Lamps: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11042 AD1 - AD2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11043 AE1 - AE2 AF Individual Trailer Lamp Inop - RH Turn/Stop/Hazard Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11044 AF1 - AF2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11045 AF3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11046 AF4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11047 AF5 AG Individual Trailer Lamp Inop - LH Turn/Stop/Hazard Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11048 AG1 - AG2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11049 AG3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11050 AG4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11051 AG5 AH Trailer Parking Lamps Inop AH1 - AH2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11052 AH3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11053 AH4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11054 AH5 - AH6 AJ Trailer Backup Lamps Inop Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11055 AJ1 - AJ2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11056 AJ3 - AJ4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11057 AJ5 - AJ6 AK Trailer Battery Charging Inop Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11058 AK1 - AK2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11059 AK3- AK4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11060 AK5 - AK6 AL Trailer Electric Brakes Inop Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11061 AL1 - AL2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11062 AL3 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11063 AL4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11064 AL5 - AL6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11065 AL7 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11066 73 Digital Multimeter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay Trailer Lighting Relay: Locations Trailer Tow Backup Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 11071 The Trailer Tow Backup Lamp Relay is located in the Power Distribution Box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 11072 Trailer Lighting Relay: Locations Trailer Tow Battery Charge Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 11073 The Trailer Tow Backup Lamp Relay is located in the Power Distribution Box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 11074 Trailer Lighting Relay: Locations Trailer Tow Left Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 11075 The Trailer Tow Backup Lamp Relay is located in the Power Distribution Box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 11076 Trailer Lighting Relay: Locations Trailer Tow Right Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 11077 The Trailer Tow Backup Lamp Relay is located in the Power Distribution Box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement Technical Service Bulletin # 99B02 Date: 990301 Campaign - Multifunction Switch Replacement 99B02 OWNER NOTIFICATION PROGRAM Certain 1997-98 Expedition and 1998 Navigator Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ All Dealer Letter: Lincoln Commitment Special Handling Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 11087 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 11088 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles that are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS PREPARATION See Sections 5 & 6 of the ACESII manual for detailed instructions. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code 99B02 Misc. Expense REFUND Misc. Expense ADMIN. Misc. Expense 0.2 Hr. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 11089 LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channel as noted. DEALER PRICE For latest prices, check or call your: -- Order Processing Center -- DOES II -- Updated Price Book EXCESS STOCK RETURN Excess stock return for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION -- Enter using DWE -- Use code information shown below: Program Code - 99B02 Labor Operation - See Above See Sections 5 & 6 of the ACESII manual for detailed instructions. To claim for the "Lincoln Commitment Special Handling", follow the instructions in Attachment IV. Attachment III - Technical Information TECHNICAL INSTRUCTIONS Please refer to Service Manual procedures: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 11090 ^ Group 2: Chassis ^ Section 211-05: Steering Column Switches ^ Removal and Installation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 11091 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 11092 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 11093 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement Technical Service Bulletin # 99B02 Date: 990301 Campaign - Multifunction Switch Replacement 99B02 OWNER NOTIFICATION PROGRAM Certain 1997-98 Expedition and 1998 Navigator Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ All Dealer Letter: Lincoln Commitment Special Handling Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 11099 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 11100 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles that are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS PREPARATION See Sections 5 & 6 of the ACESII manual for detailed instructions. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code 99B02 Misc. Expense REFUND Misc. Expense ADMIN. Misc. Expense 0.2 Hr. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 11101 LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channel as noted. DEALER PRICE For latest prices, check or call your: -- Order Processing Center -- DOES II -- Updated Price Book EXCESS STOCK RETURN Excess stock return for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION -- Enter using DWE -- Use code information shown below: Program Code - 99B02 Labor Operation - See Above See Sections 5 & 6 of the ACESII manual for detailed instructions. To claim for the "Lincoln Commitment Special Handling", follow the instructions in Attachment IV. Attachment III - Technical Information TECHNICAL INSTRUCTIONS Please refer to Service Manual procedures: Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 11102 ^ Group 2: Chassis ^ Section 211-05: Steering Column Switches ^ Removal and Installation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 11103 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 11104 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 11105 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 11109 Blower/Flasher Relay Block The Flasher Relay is located in the blower/flasher relay block. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Testing and Inspection Turn Signal Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Specifications Turn Signal Lamp: Specifications Rear Lamp Screws .............................................................................................................................. ...................................... 2.8-4.2 Nm (24.7-37.1 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Specifications > Page 11116 Turn Signal Lamp: Service and Repair REMOVAL 1. Raise the liftgate and remove the rear lamp screws. 2. Remove the rear lamp assembly. 1 Pull the rear lamp assembly outward. 2 Disconnect the electrical connector and remove the rear lamp assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 11120 Turn Signal Switch: Diagrams Multi_function Switch Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 11121 Turn Signal Switch: Description and Operation Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 11122 The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. The integrated multi-function switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer, rear wiper/washer and hazard warning. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis Turn Signal Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11125 Turn Signal Switch: Diagnostic Trouble Code Descriptions Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11126 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11127 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11128 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11129 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11130 Turn Signal Switch: Component Tests and General Diagnostics Multi-Function Switch Electrical Test 1. Measure the resistance between the multi-function switch terminals. 2. If the resistances are as specified, multi-function switch is OK. RETURN the multi-function switch to the vehicle. TEST the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11131 If the resistances are not as specified. REPLACE the multi-function switch. TEST the system for normal operation. Multi-Function Switch Component Test Multi-Function Switch - Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11132 Multi-Function Switch - Terminals Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11133 Multi-Function Switch - schematic - Dimmer,Flash To Pass,Turn/Hazard Portion Of Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11134 Turn Signal Switch: Pinout Values and Diagnostic Parameters Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11135 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 11136 Turn Signal Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Release the four clips and remove the steering column opening cover. NOTE: Move gear selector to lowest position to access steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 11137 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Description and Operation Heated Glass Control Module: Description and Operation The GEM controls the heated backlight grid and heated mirrors by controlling the state of the heated backlight/mirror relay. When the heated backlight/mirror switch is pressed, the GEM will activate the heated backlight/mirror relay. When the heated backlight/mirror relay is active, both the heated backlight grid and heated mirror elements will be energized. The GEM will deactivate the heated backlight/mirror relay when one of the following conditions is met: ^ The heated backlight/mirror switch is pressed when the feature is active. ^ Ignition switch state is changed from RUN to OFF/LOCK. ^ The 10 minute timing function is completed. Feature Inputs: ^ Ignition switch RUN position (12V on both RUN and RUN/ACC inputs). ^ Heated backlight/mirror switch (momentary contact to ground when switch is pressed). Feature Outputs: ^ Heated backlight/mirror relay control (grounded when activated, open circuit when deactivated). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Description and Operation Heated Glass Element Relay: Description and Operation The GEM controls the heated backlight grid and heated mirrors by controlling the state of the heated backlight/mirror relay. When the heated backlight/mirror switch is pressed, the GEM will activate the heated backlight/mirror relay. When the heated backlight/mirror relay is active, both the heated backlight grid and heated mirror elements will be energized. The GEM will deactivate the heated backlight/mirror relay when one of the following conditions is met: ^ The heated backlight/mirror switch is pressed when the feature is active. ^ Ignition switch state is changed from RUN to OFF/LOCK. ^ The 10 minute timing function is completed. Feature Inputs: ^ Ignition switch RUN position (12V on both RUN and RUN/ACC inputs). ^ Heated backlight/mirror switch (momentary contact to ground when switch is pressed). Feature Outputs: ^ Heated backlight/mirror relay control (grounded when activated, open circuit when deactivated). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams Rear Heated Window Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams > Page 11149 Heated Glass Element Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Pry carefully to release the clips and remove the steering column opening cover. NOTE: Position the gear shifter into low or drive 1 position. 3. Remove the headlamp switch. 4. Remove the instrument panel finish panel. 1 Remove the panel bolts. 2 Remove the instrument panel finish panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams > Page 11150 5. Disconnect the electrical connector. 6. Remove the heated backlight switch. ^ Remove the screws. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Description and Operation Heated Glass Control Module: Description and Operation The GEM controls the heated backlight grid and heated mirrors by controlling the state of the heated backlight/mirror relay. When the heated backlight/mirror switch is pressed, the GEM will activate the heated backlight/mirror relay. When the heated backlight/mirror relay is active, both the heated backlight grid and heated mirror elements will be energized. The GEM will deactivate the heated backlight/mirror relay when one of the following conditions is met: ^ The heated backlight/mirror switch is pressed when the feature is active. ^ Ignition switch state is changed from RUN to OFF/LOCK. ^ The 10 minute timing function is completed. Feature Inputs: ^ Ignition switch RUN position (12V on both RUN and RUN/ACC inputs). ^ Heated backlight/mirror switch (momentary contact to ground when switch is pressed). Feature Outputs: ^ Heated backlight/mirror relay control (grounded when activated, open circuit when deactivated). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Description and Operation Heated Glass Element Relay: Description and Operation The GEM controls the heated backlight grid and heated mirrors by controlling the state of the heated backlight/mirror relay. When the heated backlight/mirror switch is pressed, the GEM will activate the heated backlight/mirror relay. When the heated backlight/mirror relay is active, both the heated backlight grid and heated mirror elements will be energized. The GEM will deactivate the heated backlight/mirror relay when one of the following conditions is met: ^ The heated backlight/mirror switch is pressed when the feature is active. ^ Ignition switch state is changed from RUN to OFF/LOCK. ^ The 10 minute timing function is completed. Feature Inputs: ^ Ignition switch RUN position (12V on both RUN and RUN/ACC inputs). ^ Heated backlight/mirror switch (momentary contact to ground when switch is pressed). Feature Outputs: ^ Heated backlight/mirror relay control (grounded when activated, open circuit when deactivated). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Description and Operation Power Window Control Module: Description and Operation The Generic Electronic Module (GEM) controls the opening of the LF driver side power window (window down motion) by activating the One Touch Down (OTD)relay. There are two modes of window down operation, manual and auto mode. The manual mode is selected by pressing the LF window switch to the first (down) position. In manual mode the window will move downward only while the switch is depressed. When the LF window switch is pressed to the second (down) position, it enters auto mode and the window will open completely with just a momentary press of the switch. The GEM will activate the OTD Relay until one of the following conditions is met: - The LF regulator control switch is pushed to the UP position. - The LF regulator control switch is released (OFF position) and then moved to the down position (first detent) or one touch down position (second detent). - Seven seconds have elapsed since the OTD was initiated. - A window regulator electric drive stall condition is detected on the one touch down sense line inputs. The UP window operation is not controlled by the GEM. The feature is activated when the delayed accessory is active and the LF window regulator control switch is pressed to the UP position. The switch provides delayed accessory power to one side of the motor and ground to the other side through the one touch down relay. The one touch down relay is not active when the LF regulator control switch is in the UP position. Passenger windows may be raised or lowered using the LF master control switches or the appropriate passenger window switch. Passenger window switches receive power when the delayed accessory relay is active and the LF remote lock-out switch is in the UNLOCK position. When in the LOCK-OUT position, the passenger windows are deactivated. The GEM controls manual down and auto down window movement with the down window relay. The relay is activated by applying ground directly to one side of the down window relay coil, and deactivated by removing the ground signal. The delayed accessory relay provides power for the operation of the power windows and the power moon roof. The delayed accessory feature is active when the ignition switch is in the RUN or the ACC position, or when the ignition switch is changed from RUN or ACC to the OFF/LOCK position and the LF and RF doors are closed. The GEM will deactivate the delayed accessory feature when: - The LF door is ajar and the ignition switch is in the OFF/LOCK or KEY-OUT position. - The RF door is ajar and the ignition switch is in the OFF/LOCK or KEY-OUT position. - 10 minutes have elapsed since the ignition switch was changed from ACC or RUN to the OFF/LOCK position. Feature Inputs: - LF door open warning switch (open circuit with door closed, grounded with door ajar). - RF door open warning switch (open circuit with door closed, grounded with door ajar). - Ignition switch RUN position (battery potential on both the RUN and RUN/ACC inputs). - Ignition switch ACC position (battery potential on the RUN/ACC input). - Ignition switch OFF/LOCK position (absence of battery potential on the RUN, RUN/ACC, and START inputs). Feature Outputs: - Delayed accessory relay (grounded when activated, open circuit when deactivated). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 11164 Junction Box Fuse/Relay Panel (Part 1 Of 2) The One Touch Down Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Rear Heated Window Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 11169 Heated Glass Element Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Pry carefully to release the clips and remove the steering column opening cover. NOTE: Position the gear shifter into low or drive 1 position. 3. Remove the headlamp switch. 4. Remove the instrument panel finish panel. 1 Remove the panel bolts. 2 Remove the instrument panel finish panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 11170 5. Disconnect the electrical connector. 6. Remove the heated backlight switch. ^ Remove the screws. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Power Window Control Switch Power Window Switch: Locations Power Window Control Switch The window regulator control switch is located on each door trim panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Power Window Control Switch > Page 11175 Power Window Switch: Locations Rear Quarter Glass Regulator Control Switches The rear quarter glass regulator control switches are located in the overhead console. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch Power Window Switch: Diagrams Power Window Switch Left Front Power Window Switch (C510) Left Front Power Window Switch (C509) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 11178 Right Front Power Window Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 11179 Power Window Switch: Diagrams Rear Power Window Switch Left Rear Window Switch Right Rear Window Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 11180 Power Window Switch: Diagrams Vent Window Switch Left Rear Vent Window Switch Right Rear Vent Window Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Rear Quarter Glass Regulator Control Switches Power Window Switch: Description and Operation Rear Quarter Glass Regulator Control Switches The rear quarter glass regulator control switches: - Are located in the overhead console. - May be used to open and close the RH or LH rear quarter windows. - Stop the rear quarter glass in any position when released. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Rear Quarter Glass Regulator Control Switches > Page 11183 Power Window Switch: Description and Operation Window Regulator Control Switch The window regulator control switch: - Is located on each door trim panel. - May be used to raise or lower all windows from the master control on the driver side, or the individual side window from the individual door switch. - Includes a "double detent" feature. - Can manually lower the driver side window when the master control is depressed half way (first detent). - Will completely lower the driver side window when the master control is fully depressed and then released (second detent). - Can lock out passenger front and rear control switches. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Description and Operation Power Window Control Module: Description and Operation The Generic Electronic Module (GEM) controls the opening of the LF driver side power window (window down motion) by activating the One Touch Down (OTD)relay. There are two modes of window down operation, manual and auto mode. The manual mode is selected by pressing the LF window switch to the first (down) position. In manual mode the window will move downward only while the switch is depressed. When the LF window switch is pressed to the second (down) position, it enters auto mode and the window will open completely with just a momentary press of the switch. The GEM will activate the OTD Relay until one of the following conditions is met: - The LF regulator control switch is pushed to the UP position. - The LF regulator control switch is released (OFF position) and then moved to the down position (first detent) or one touch down position (second detent). - Seven seconds have elapsed since the OTD was initiated. - A window regulator electric drive stall condition is detected on the one touch down sense line inputs. The UP window operation is not controlled by the GEM. The feature is activated when the delayed accessory is active and the LF window regulator control switch is pressed to the UP position. The switch provides delayed accessory power to one side of the motor and ground to the other side through the one touch down relay. The one touch down relay is not active when the LF regulator control switch is in the UP position. Passenger windows may be raised or lowered using the LF master control switches or the appropriate passenger window switch. Passenger window switches receive power when the delayed accessory relay is active and the LF remote lock-out switch is in the UNLOCK position. When in the LOCK-OUT position, the passenger windows are deactivated. The GEM controls manual down and auto down window movement with the down window relay. The relay is activated by applying ground directly to one side of the down window relay coil, and deactivated by removing the ground signal. The delayed accessory relay provides power for the operation of the power windows and the power moon roof. The delayed accessory feature is active when the ignition switch is in the RUN or the ACC position, or when the ignition switch is changed from RUN or ACC to the OFF/LOCK position and the LF and RF doors are closed. The GEM will deactivate the delayed accessory feature when: - The LF door is ajar and the ignition switch is in the OFF/LOCK or KEY-OUT position. - The RF door is ajar and the ignition switch is in the OFF/LOCK or KEY-OUT position. - 10 minutes have elapsed since the ignition switch was changed from ACC or RUN to the OFF/LOCK position. Feature Inputs: - LF door open warning switch (open circuit with door closed, grounded with door ajar). - RF door open warning switch (open circuit with door closed, grounded with door ajar). - Ignition switch RUN position (battery potential on both the RUN and RUN/ACC inputs). - Ignition switch ACC position (battery potential on the RUN/ACC input). - Ignition switch OFF/LOCK position (absence of battery potential on the RUN, RUN/ACC, and START inputs). Feature Outputs: - Delayed accessory relay (grounded when activated, open circuit when deactivated). Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Specifications Power Window Motor: Specifications Window Regulator Nuts ....................................................................................................................... ............................................ 10-14 Nm (7.4-10 ft lb) Power Window Motor Bolts ........................................................................................................................................................... 5.6-9.1 Nm (50-81 in lb) Window Glass to Regulator Nuts ..................................................................................................................................................... 10-14 Nm (7.4-10 ft lb) Rear Quarter Glass Motor Nuts .............................................................................................................................................. 7.6-10.4 Nm (67.8-92.7 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Rear Door Window Motor Power Window Motor: Service and Repair Rear Door Window Motor Heavy Duty Riverter Special Tool(s) REMOVAL NOTE: The window regulator and motor are removed as an assembly. 1. Remove the rear door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors 2. Remove the rear door radio speaker. 3. Remove the rear door watershield. 4. Raise and support the rear door window glass to the full up position. CAUTION: Support the window glass to avoid damage. 5. Disconnect the power window motor electrical connector. 6. Remove the window glass to regulator nuts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Rear Door Window Motor > Page 11193 7. Remove the motor and window regulator assembly. 1 Drill out the rivets. 2 Remove the motor and window regulator assembly. 8. Remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. NOTE: Prior to motor removal, ensure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy Duty Riveter to install the new rivets. - Cycle the door glass to ensure gear engagement. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Rear Door Window Motor > Page 11194 Power Window Motor: Service and Repair Rear Quarter Window Motor REMOVAL 1. Remove the quarter trim panel. 2. Unclip the quarter window regulator from the quarter window. 3. Remove the rear quarter glass motor. 1 Disconnect the electrical connector. 2 Remove the nuts and the rear quarter glass motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Rear Door Window Motor > Page 11195 Power Window Motor: Service and Repair Front Door Window Motor Heavy Duty Riverter Special Tool(s) REMOVAL NOTE: The window regulator and motor are removed as an assembly. 1. Remove the front door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors 2. Remove the front door radio speaker. 3. Remove the front door watershield. 4. Raise and support the front door window glass to the full up position. CAUTION: Support the window glass to avoid damage. 5. Disconnect the power window motor electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Rear Door Window Motor > Page 11196 6. Remove the window glass to regulator nuts. 7. Remove the motor and window regulator assembly. 1 Drill out the rivets. 2 Remove the motor and window regulator assembly. 8. Remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. NOTE: Prior to motor removal, ensure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Rear Door Window Motor > Page 11197 1. To install, reverse the removal procedure. - Use Heavy Duty Riveter to install the new rivets. - Cycle the door glass to ensure gear engagement. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations Power Window Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 11201 Junction Box Fuse/Relay Panel (Part 1 Of 2) The One Touch Down Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Power Window Control Switch Power Window Switch: Locations Power Window Control Switch The window regulator control switch is located on each door trim panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Power Window Control Switch > Page 11206 Power Window Switch: Locations Rear Quarter Glass Regulator Control Switches The rear quarter glass regulator control switches are located in the overhead console. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch Power Window Switch: Diagrams Power Window Switch Left Front Power Window Switch (C510) Left Front Power Window Switch (C509) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 11209 Right Front Power Window Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 11210 Power Window Switch: Diagrams Rear Power Window Switch Left Rear Window Switch Right Rear Window Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 11211 Power Window Switch: Diagrams Vent Window Switch Left Rear Vent Window Switch Right Rear Vent Window Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > Rear Quarter Glass Regulator Control Switches Power Window Switch: Description and Operation Rear Quarter Glass Regulator Control Switches The rear quarter glass regulator control switches: - Are located in the overhead console. - May be used to open and close the RH or LH rear quarter windows. - Stop the rear quarter glass in any position when released. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > Rear Quarter Glass Regulator Control Switches > Page 11214 Power Window Switch: Description and Operation Window Regulator Control Switch The window regulator control switch: - Is located on each door trim panel. - May be used to raise or lower all windows from the master control on the driver side, or the individual side window from the individual door switch. - Includes a "double detent" feature. - Can manually lower the driver side window when the master control is depressed half way (first detent). - Will completely lower the driver side window when the master control is fully depressed and then released (second detent). - Can lock out passenger front and rear control switches. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the front door radio speaker. 3. Remove the front door watershield. 4. Lower the window glass to access the two window glass to regulator nuts. 5. Remove the inside glass weatherstrip. 6. Remove the front door rear glass channel bolt and position the channel aside. 7. Remove the window glass to regulator nuts. 8. Remove the front door window glass. NOTE: Slide the glass through the outboard side of the door. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Page 11219 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair REMOVAL 1. Disconnect the heated backlite electrical connector. 2. Remove the liftgate trim panels. 3. Disconnect the liftgate window glass support. 1 Remove the E-clip. 2 Remove the pin. 3 Disconnect the support. NOTE: Have an assistant hold the liftgate window glass. 4. Remove the liftgate window glass. 1 Remove the four bolts (two each side). 2 Remove the liftgate window glass. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 11223 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed Quarter Window Glass: Service and Repair Fixed REMOVAL 1. Remove the quarter trim panel. 2. Remove the rear quarter window glass. 1 Remove the nuts. 2 Carefully push the rear quarter window glass outward to release the foam butyl seal. NOTE: Have an assistant hold the rear quarter window glass. 3. Remove the excess foam butyl from the window opening. INSTALLATION 1. Apply 8 mm Foam Butyl (part of EOAZ-19562-A), or equivalent meeting Ford specification WSB-M2G234-C to the rear quarter window glass frame. Start at the bottom middle and work around the frame. NOTE: When applying foam butyl, leave a slight overlap at the bottom to allow for drainage. 2. Install the rear quarter window glass. 1 Position the rear quarter window glass. 2 Install quarter window glass nuts. NOTE: Loosely install all the nuts before tightening. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed > Page 11228 3. Install the quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed > Page 11229 Quarter Window Glass: Service and Repair Vented Glass REMOVAL 1. Remove the quarter trim panel. 2. Remove the C-pillar trim panel. 3. Remove the D-pillar trim panel. 4. Unclip the quarter window regulator from the quarter window. 5. Remove the quarter window glass. 1 Remove the nuts. 2 Remove the quarter window glass. NOTE: Have an assistant hold the rear quarter window glass. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed > Page 11230 1. To install, reverse the removal procedure. Frame REMOVAL 1. Remove the vented rear quarter window glass. 2. Remove the quarter window glass frame. 1 Remove the ten nuts. 2 Remove the quarter window glass frame. 3. Clean the excess foam butyl from the window opening. INSTALLATION 1. Apply 8 mm Foam Butyl (part of EOAZ-19562-A) or equivalent meeting Ford specification WSB-M2G234-C to the rear quarter window glass frame. Start at the bottom middle and work around the frame. NOTE: When applying foam butyl, leave a slight overlap at the bottom to allow for drainage. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed > Page 11231 2. Install the rear quarter window glass frame. 1 Position the rear quarter window glass frame. 2 Install the ten nuts. NOTE: Loosely install all the nuts before tightening. 3. Install the rear quarter window glass. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL 1. Remove the rear door trim panel. 2. Remove the rear door radio speaker. 3. Remove the rear door watershield. 4. Remove the inside glass weatherstrip. 5. Remove the rear door glass channel lower bolt. 6. Remove the rear door fixed vent screw. 7. Lift the rear door rear glass and channel away from the door glass. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Page 11235 8. Remove the window glass to regulator nuts. 9. Remove the rear door glass. NOTE: Slide the glass through the outboard side of the door. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) 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 Heavy Duty Riverter Special Tool(s) REMOVAL NOTE: The window regulator and motor are removed as an assembly. 1. Remove the front door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors 2. Remove the front door radio speaker. 3. Remove the front door watershield. 4. Raise and support the front door window glass to the full up position. CAUTION: Support the window glass to avoid damage. 5. Disconnect the power window motor electrical connector. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 11240 6. Remove the window glass to regulator nuts. 7. Remove the motor and window regulator assembly. 1 Drill out the rivets. 2 Remove the motor and window regulator assembly. 8. Remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. NOTE: Prior to motor removal, ensure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 11241 1. To install, reverse the removal procedure. - Use Heavy Duty Riveter to install the new rivets. - Cycle the door glass to ensure gear engagement. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Window Regulator Nuts ....................................................................................................................... ............................................ 10-14 Nm (7.4-10 ft lb) Power Window Motor Bolts ........................................................................................................................................................... 5.6-9.1 Nm (50-81 in lb) Window Glass to Regulator Nuts ..................................................................................................................................................... 10-14 Nm (7.4-10 ft lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications > Page 11245 Rear Door Window Regulator: Service and Repair Heavy Duty Riverter Special Tool(s) REMOVAL NOTE: The window regulator and motor are removed as an assembly. 1. Remove the rear door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors 2. Remove the rear door radio speaker. 3. Remove the rear door watershield. 4. Raise and support the rear door window glass to the full up position. CAUTION: Support the window glass to avoid damage. 5. Disconnect the power window motor electrical connector. 6. Remove the window glass to regulator nuts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications > Page 11246 7. Remove the motor and window regulator assembly. 1 Drill out the rivets. 2 Remove the motor and window regulator assembly. 8. Remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. NOTE: Prior to motor removal, ensure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy Duty Riveter to install the new rivets. - Cycle the door glass to ensure gear engagement. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel Window Track: Customer Interest Body - Front Window(s) Pop/Thump Noise at End of Travel Article No. 04-5-7 03/22/04 BODY - FRONT WINDOW(S) - POP/THUMP NOISE AT END OF WINDOW TRAVEL AND/OR DRIVER'S WINDOW BOUNCE BACK AND REVERSE TO MID-POSITION FORD: 1997-2003 F-150 1997-2004 EXPEDITION LINCOLN: 1998-2004 NAVIGATOR ISSUE Some 1997-2004 Expedition, 1998-2004 Navigator built through 04/01/2004 and 1997-2003 F-150, may exhibit a pop/thump noise at the end of window travel when either front window is rolled up. Some 2003-2004 Navigator vehicles may also exhibit a driver's door glass bounce back and reverse to a mid-position. The condition may exist when the vehicle is stationary or traveling at low speeds, however the condition will become more pronounced when traveling at higher speeds. This may be due to the window glass being too far outboard and catching on the glass run before seating. ACTION To service, adjust the window's travel path inward, by bending the flange on which the glass run is mounted. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Remove inner door panel, refer to Workshop Manual Section 501-11. 2. Remove exterior mirror, refer to Workshop Manual Section 501-09. 3. Torque door glass retainers for regulator to door, window glass to regulator, and both front and rear window runs to 11 N.m (8 lb-ft). 4. Lower door glass to position it out of the way. 5. Remove inner and outer belt molding. 6. Position aside front window run. a. Remove retainer. b. Position outside of work area. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 11255 7. Bend flange inboard about 10 degrees, using a pair of sheet metal clamp locking pliers (Figure 1). Starting at the bend at the top of the sail plate, and working down approximately 25.40 cm (10") (Figure 2). NOTE TAKE CARE NOT TO OVER BEND FLANGE, THIS MAY INDUCE WIND NOISE. 8. Reposition front window run. a. Install retainer. b. Torque retainer to 11 N.m (8 lb-ft). 9. Install inner and outer belt molding. 10. Install exterior mirror, refer to Workshop Manual Section 501-09. 11. Install inner door panel, refer to Workshop Manual Section 501-11. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 11256 12. 2003-2004 Navigator vehicles, re-initialize drivers window according to Workshop Manual Section 501-11. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7820125 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel Window Track: All Technical Service Bulletins Body - Front Window(s) Pop/Thump Noise at End of Travel Article No. 04-5-7 03/22/04 BODY - FRONT WINDOW(S) - POP/THUMP NOISE AT END OF WINDOW TRAVEL AND/OR DRIVER'S WINDOW BOUNCE BACK AND REVERSE TO MID-POSITION FORD: 1997-2003 F-150 1997-2004 EXPEDITION LINCOLN: 1998-2004 NAVIGATOR ISSUE Some 1997-2004 Expedition, 1998-2004 Navigator built through 04/01/2004 and 1997-2003 F-150, may exhibit a pop/thump noise at the end of window travel when either front window is rolled up. Some 2003-2004 Navigator vehicles may also exhibit a driver's door glass bounce back and reverse to a mid-position. The condition may exist when the vehicle is stationary or traveling at low speeds, however the condition will become more pronounced when traveling at higher speeds. This may be due to the window glass being too far outboard and catching on the glass run before seating. ACTION To service, adjust the window's travel path inward, by bending the flange on which the glass run is mounted. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Remove inner door panel, refer to Workshop Manual Section 501-11. 2. Remove exterior mirror, refer to Workshop Manual Section 501-09. 3. Torque door glass retainers for regulator to door, window glass to regulator, and both front and rear window runs to 11 N.m (8 lb-ft). 4. Lower door glass to position it out of the way. 5. Remove inner and outer belt molding. 6. Position aside front window run. a. Remove retainer. b. Position outside of work area. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 11262 7. Bend flange inboard about 10 degrees, using a pair of sheet metal clamp locking pliers (Figure 1). Starting at the bend at the top of the sail plate, and working down approximately 25.40 cm (10") (Figure 2). NOTE TAKE CARE NOT TO OVER BEND FLANGE, THIS MAY INDUCE WIND NOISE. 8. Reposition front window run. a. Install retainer. b. Torque retainer to 11 N.m (8 lb-ft). 9. Install inner and outer belt molding. 10. Install exterior mirror, refer to Workshop Manual Section 501-09. 11. Install inner door panel, refer to Workshop Manual Section 501-11. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 11263 12. 2003-2004 Navigator vehicles, re-initialize drivers window according to Workshop Manual Section 501-11. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7820125 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks Windshield: Customer Interest Windshield - Water Leaks Article No. 99-2-3 ^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP ^ WINDSHIELD - SEALING - SERVICE TIP FORD: 1995-97 PROBE, THUNDERBIRD 1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield. ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip removal where necessary. NOTE DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO ENSURE REPAIR OF THE LEAK. The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times: ^ 03100B PART NUMBER PART NAME F8AZ-19554-CA Liquid Butyl Sealer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 11272 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 110000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems Technical Service Bulletin # 98-9-13 Date: 980511 Body/Frame - Water Leaks Causing Electrical Problems Article No. 98-9-13 05/11/98 ^ WATER LEAKS - VARIOUS AREAS OF VEHICLE ^ ELECTRICAL - ACCESSORIES FUNCTIONING IMPROPERLY DUE TO WATER LEAKS ^ LAMPS - WARNING LAMPS ILLUMINATED DUE TO WATER LEAKS LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to add F-150, F-250 LD, and Navigator vehicles, and to revise the text and art accordingly. ISSUE Water leaks in various areas of the vehicle as identified below may be causing electrical concerns such as: ^ Warning lamps illuminating, and/or ^ Improper wiper operation, and/or ^ Improper function of electrical accessories The water leaks may be caused by sealer skips, unseated grommets, and/or clogged drain tubes. ACTION Repair the water leaks. Refer to the following Service Procedures for details on: ^ Windshield Leaks ^ Cowl Top Leaks ^ Cowl Side-to-Door Opening Panel Leaks ^ Cowl Side-to-Dash Panel Leaks ^ Moon roof Leaks ^ Grommets The following procedures may include using a seam sealer for repairs. Recommended seam sealers are: Company Part Name Phone Number 3M Ultrapro Seam Sealer (612) 733-5547 - US Kent Uniweld Seam Sealer (800) 654-6333 - US (800) 663-2800 - Canada OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-19-15 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11277 980913A Windshield Leaks Service 0.5 Hr. Procedure 980913B Additional Time If Leaf 0.4 Hr. Screen Must Be Removed (Used With Operation A) 980913C Cowl Top Leaks Service 1.3 Hrs. Procedure 980913D Cowl Side-To-Door 1.9 Hrs. Opening Panel Leaks Service Procedure 980913E Cowl Side-To-Dash Panel 0.4 Hr. Leaks Service Procedure 980913F Moonroof Leaks Service 0.4 Hr. Procedure 980913G Grommets Service 0.4 Hr. Procedure DEALER CODING CONDITION BASIC PART NO. CODE 18812 GROMMET(S) LEAKS 68 7801610 COWL TOP LEAKS (DASH PANEL) 68 7802012 COWL TOP LEAKS (OUTER) 68 7802018 COWL SIDE TO-DASH PANEL LEAKS 68 7802039 COWL SIDE-TO-DOOR OPENING PANEL LEAKS 68 7803100 WINDSHIELD LEAKS 68 78502C53 MOON ROOF LEAKS 68 OASIS CODES: 110000,190000, 202000, 203000, 205000, 206000 Windshield Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11278 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11279 Refer To Figures 1, 2, and 3 1. Remove A-pillar mouldings, rocker panel scuff plates, and cowl lower scuff plates. Refer to the appropriate Workshop Manual, Section 501-05. 2. Apply a water hose at the bottom center of the windshield and slowly move outboard at a rate of 305 mm (1 foot) per 15-20 seconds. Then move up one side, inboard along top of header to the center. Lift the moulding at top of windshield to allow water to pass through windshield moulding. NOTE A NARROW NYLON TIP ON THE END OF THE HOSE WILL ALLOW THE OPERATOR TO EASILY SLIDE THE TIP UNDER THE MOULDING AND SLOWLY MOVE IT ALONG THE INSIDE SURFACE. 3. To determine if water is entering, have an observer use a flashlight to watch for water as the hose is being moved. The observer should start looking at the dash back panel by pulling back the dash insulator pad above the water location. 4. If a leak is detected, document the location and path for future reference. 5. Fill any voids with pumpable Butyl Sealer. NOTE TO REPAIR WATER LEAKS FOUND AT THE BASE OF THE WINDSHIELD, THE LEAF SCREEN MUST FIRST BE REMOVED. Cowl Top Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11280 Refer To Figure 4 1. Remove the leaf screen by referring to the appropriate Workshop Manual, Section 501-02. 2. Spray water into cowl top-to-dash panel seam. Spray for up to 20 minutes. 3. Inspect the inner dash panel for water intrusion, starting at the bottom of the cowl area. 4. With the trim rocker cover and kick plate removed, pull back carpet and inspect for water. 5. If no water is found, look in the area of the cross car beam and/or lower windshield "VIN tag" area. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11281 6. Seal inner cowl with seam sealer. Cowl Side-to-Door Opening Panel Leaks Service Procedure Refer To Figure 5 1. Remove the left front tire. 2. Remove the inner fender splash shield from the left front fender. Refer to the appropriate Workshop Manual, Section 501-02, for details. 3. Remove the grille by referring to the Workshop Manual, Section 501-08. 4. Remove the left front fender by referring to the Workshop Manual, Section 501-02. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11282 5. Test with water. 6. Apply seam sealer along the interface between the cowl and the dash panel. This area can be reached through the access hole located near the top hinge for the front door. 7. Reassemble in reverse order. 8. Apply paint protection to fender bolts. Cowl Side-to-Dash Panel Leaks Service Procedure Refer To Figure 6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11283 1. Remove rocker cover and lower scuff panel by referring to the appropriate Workshop Manual, Section 501-05. 2. Inspect dash panel-to-cowl side inner sealer for skips and/or missing sealer. 3. Test with water at the top of the cowl/leaf screen area and inspect the vehicle for water entry. 4. Apply seam sealer along the interface between the cowl, dash, and floor panel. Moonroof Leaks Service Procedure Refer To Figure 7 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11284 1. Before beginning any diagnosis, contact the Webasto Tech Hotline at (800) 995-5911 Monday-Friday, 9AM-6PM EST. 2. Cycle moonroof to open position. 3. Check for proper drain tube action by pouring approximately 1.8L (6 oz) of water into trough at each side. 4. If tubes appear to be draining properly, remove the interior A-pillar trim and sun visors. Refer to the appropriate Workshop Manual, Section 501-05. 5. Pull down the headliner slightly and inspect moonroof drain tubes for kinks and/or twists. The drain tubes must be free from any bends or obstruction of water flow. 6. Straighten or cut drain tubes to proper length to allow for free draining. Grommets Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11285 Refer To Figure 8 1. Check for missing or improperly seated grommets in the following areas: ^ Antenna grommet on passenger side cowl ^ Park brake cable grommet on driver side cowl ^ Overall instrument panel grommets 2. Reseat any loose grommets or replace any missing grommets. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks Windshield: All Technical Service Bulletins Windshield - Water Leaks Article No. 99-2-3 ^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP ^ WINDSHIELD - SEALING - SERVICE TIP FORD: 1995-97 PROBE, THUNDERBIRD 1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield. ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip removal where necessary. NOTE DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO ENSURE REPAIR OF THE LEAK. The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times: ^ 03100B PART NUMBER PART NAME F8AZ-19554-CA Liquid Butyl Sealer Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 11291 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 110000 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems Technical Service Bulletin # 98-9-13 Date: 980511 Body/Frame - Water Leaks Causing Electrical Problems Article No. 98-9-13 05/11/98 ^ WATER LEAKS - VARIOUS AREAS OF VEHICLE ^ ELECTRICAL - ACCESSORIES FUNCTIONING IMPROPERLY DUE TO WATER LEAKS ^ LAMPS - WARNING LAMPS ILLUMINATED DUE TO WATER LEAKS LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to add F-150, F-250 LD, and Navigator vehicles, and to revise the text and art accordingly. ISSUE Water leaks in various areas of the vehicle as identified below may be causing electrical concerns such as: ^ Warning lamps illuminating, and/or ^ Improper wiper operation, and/or ^ Improper function of electrical accessories The water leaks may be caused by sealer skips, unseated grommets, and/or clogged drain tubes. ACTION Repair the water leaks. Refer to the following Service Procedures for details on: ^ Windshield Leaks ^ Cowl Top Leaks ^ Cowl Side-to-Door Opening Panel Leaks ^ Cowl Side-to-Dash Panel Leaks ^ Moon roof Leaks ^ Grommets The following procedures may include using a seam sealer for repairs. Recommended seam sealers are: Company Part Name Phone Number 3M Ultrapro Seam Sealer (612) 733-5547 - US Kent Uniweld Seam Sealer (800) 654-6333 - US (800) 663-2800 - Canada OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-19-15 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11296 980913A Windshield Leaks Service 0.5 Hr. Procedure 980913B Additional Time If Leaf 0.4 Hr. Screen Must Be Removed (Used With Operation A) 980913C Cowl Top Leaks Service 1.3 Hrs. Procedure 980913D Cowl Side-To-Door 1.9 Hrs. Opening Panel Leaks Service Procedure 980913E Cowl Side-To-Dash Panel 0.4 Hr. Leaks Service Procedure 980913F Moonroof Leaks Service 0.4 Hr. Procedure 980913G Grommets Service 0.4 Hr. Procedure DEALER CODING CONDITION BASIC PART NO. CODE 18812 GROMMET(S) LEAKS 68 7801610 COWL TOP LEAKS (DASH PANEL) 68 7802012 COWL TOP LEAKS (OUTER) 68 7802018 COWL SIDE TO-DASH PANEL LEAKS 68 7802039 COWL SIDE-TO-DOOR OPENING PANEL LEAKS 68 7803100 WINDSHIELD LEAKS 68 78502C53 MOON ROOF LEAKS 68 OASIS CODES: 110000,190000, 202000, 203000, 205000, 206000 Windshield Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11297 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11298 Refer To Figures 1, 2, and 3 1. Remove A-pillar mouldings, rocker panel scuff plates, and cowl lower scuff plates. Refer to the appropriate Workshop Manual, Section 501-05. 2. Apply a water hose at the bottom center of the windshield and slowly move outboard at a rate of 305 mm (1 foot) per 15-20 seconds. Then move up one side, inboard along top of header to the center. Lift the moulding at top of windshield to allow water to pass through windshield moulding. NOTE A NARROW NYLON TIP ON THE END OF THE HOSE WILL ALLOW THE OPERATOR TO EASILY SLIDE THE TIP UNDER THE MOULDING AND SLOWLY MOVE IT ALONG THE INSIDE SURFACE. 3. To determine if water is entering, have an observer use a flashlight to watch for water as the hose is being moved. The observer should start looking at the dash back panel by pulling back the dash insulator pad above the water location. 4. If a leak is detected, document the location and path for future reference. 5. Fill any voids with pumpable Butyl Sealer. NOTE TO REPAIR WATER LEAKS FOUND AT THE BASE OF THE WINDSHIELD, THE LEAF SCREEN MUST FIRST BE REMOVED. Cowl Top Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11299 Refer To Figure 4 1. Remove the leaf screen by referring to the appropriate Workshop Manual, Section 501-02. 2. Spray water into cowl top-to-dash panel seam. Spray for up to 20 minutes. 3. Inspect the inner dash panel for water intrusion, starting at the bottom of the cowl area. 4. With the trim rocker cover and kick plate removed, pull back carpet and inspect for water. 5. If no water is found, look in the area of the cross car beam and/or lower windshield "VIN tag" area. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11300 6. Seal inner cowl with seam sealer. Cowl Side-to-Door Opening Panel Leaks Service Procedure Refer To Figure 5 1. Remove the left front tire. 2. Remove the inner fender splash shield from the left front fender. Refer to the appropriate Workshop Manual, Section 501-02, for details. 3. Remove the grille by referring to the Workshop Manual, Section 501-08. 4. Remove the left front fender by referring to the Workshop Manual, Section 501-02. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11301 5. Test with water. 6. Apply seam sealer along the interface between the cowl and the dash panel. This area can be reached through the access hole located near the top hinge for the front door. 7. Reassemble in reverse order. 8. Apply paint protection to fender bolts. Cowl Side-to-Dash Panel Leaks Service Procedure Refer To Figure 6 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11302 1. Remove rocker cover and lower scuff panel by referring to the appropriate Workshop Manual, Section 501-05. 2. Inspect dash panel-to-cowl side inner sealer for skips and/or missing sealer. 3. Test with water at the top of the cowl/leaf screen area and inspect the vehicle for water entry. 4. Apply seam sealer along the interface between the cowl, dash, and floor panel. Moonroof Leaks Service Procedure Refer To Figure 7 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11303 1. Before beginning any diagnosis, contact the Webasto Tech Hotline at (800) 995-5911 Monday-Friday, 9AM-6PM EST. 2. Cycle moonroof to open position. 3. Check for proper drain tube action by pouring approximately 1.8L (6 oz) of water into trough at each side. 4. If tubes appear to be draining properly, remove the interior A-pillar trim and sun visors. Refer to the appropriate Workshop Manual, Section 501-05. 5. Pull down the headliner slightly and inspect moonroof drain tubes for kinks and/or twists. The drain tubes must be free from any bends or obstruction of water flow. 6. Straighten or cut drain tubes to proper length to allow for free draining. Grommets Service Procedure Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11304 Refer To Figure 8 1. Check for missing or improperly seated grommets in the following areas: ^ Antenna grommet on passenger side cowl ^ Park brake cable grommet on driver side cowl ^ Overall instrument panel grommets 2. Reseat any loose grommets or replace any missing grommets. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 11305 Windshield: Specifications 8 mm Foam Butyl (Part of EOAZ-19562-A) ............................................................................................................................................. WSB-M2G234-C Urethane Glass Prep (Part of EOAZ-19562-A) ......................................................................................................................................... WSB-M2G234-C Urethane Metal Primer (Part of EOAZ-19562-A) ..................................................................................................................................... WSB-M2G314-B Urethane Sealant (Part of EOAZ-19562-A) ............................................................................................................................................... WSB-M2G316-B Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 11306 Windshield: Service Precautions WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 11307 Windshield: Description and Operation The glass and frames include: ^ Standard plastic and laminate safety glass. ^ Windshield glass which is bonded to the opening flange with a urethane sealant. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 11308 Windshield: Service and Repair Interior Auto Glass Cut-Out Knife Kit Special Tool(s) REMOVAL 1. Remove the cowl top vent panels. 2. Remove the windshield side garnish mouldings. 3. Remove the inside rear view mirror. 4. Lower the front portion of the roof trim panel. 5. Remove the upper windshield weatherstrip. 6. Remove the LH and RH windshield mouldings. 7. Mark the outside of the windshield glass with a wax pencil to avoid damaging the glass stops when cutting the urethane. 8. Lubricate the Urethane Sealant with water to aid Interior Auto Glass Cut-Out Knife Kit while cutting. 9. Use Interior Auto Glass Cut-Out Knife Kit to cut the Urethane Sealant from the windshield glass. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 11309 ^ Insert the blade into the urethane at the top middle and work toward the bottom corners. WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE. 10. Trim the excess Urethane Sealant from the outside edge of the windshield glass. 11. Carefully remove the windshield glass. NOTE: Removing the windshield glass requires more than one technician. 12. Trim the remaining Urethane Sealant on the pinch weld to within specification. ^ The old urethane surface should be smooth and free of cuts and contamination. INSTALLATION CAUTION: After replacing the urethane installed glass, the vehicle should not be driven until the Urethane Sealant has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours(decreasing at higher temperatures and lower humidities). Inadequate curing of the Urethane Sealant may adversely affect the strength of the Urethane Sealant bond. 1. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, or rust or foreign material that could cause glass damage. 2. Use the wool applicator to apply Urethane Metal Primer (part of EOAZ-19562-A), or equivalent meeting Ford specification WSB-M2G314-B to any exposed metal on the pinch weld. 3. Apply 8 mm Foam Butyl (part of EOAZ-19562-A) or equivalent meeting Ford specification WSB-M2G234-C to the pinch weld. 4. Remove excess Urethane Sealant from the windshield glass. 5. Clean the inside of the glass surface with an alcohol-free cleaner. 6. Apply Urethane Glass Prep (part of EOAZ-19562-A) or equivalent meeting Ford specification WSB-M2G234-C twice around the glass surface to Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 11310 be urethaned. NOTE: ^ Apply with deliberate strokes, making sure not to overlap applied area. ^ Wipe off the Urethane Glass Prep immediately after application because it flash dries. 7. Cut the urethane applicator tip to specification. 8. Apply a bead of Urethane Sealant (part of EOAZ- 19562-A) or equivalent meeting Ford specification WSB-M2G316-B to the pinch weld just outside the foam butyl dam. 9. Install the inside rear view mirror. 10. Position the windshield glass. 11. Install the upper windshield weatherstrip. 12. Paddle the excess Urethane Sealant from the two sides of the windshield glass. NOTE: Use one continuous stroke when removing the excess Urethane Sealant. 13. If necessary, remove excess Urethane Sealant from the outside surface of the windshield glass. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 11311 14. Install the LH and RH windshield mouldings. 15. Install the roof trim panel. 16. Install the windshield side garnish mouldings. 17. Install the cowl top vent panels. 18. Install the windshield wiper pivot arms and adjust if necessary. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay Windshield Washer Relay: Locations Front Washer Pump Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 11318 Power Distribution Box The Front Washer Pump Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 11319 Windshield Washer Relay: Locations Rear Washer Pump Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 11320 Power Distribution Relay Box The Rear Washer Pump Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay Wiper Relay: Locations Rear Wiper Down Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 11325 Power Distribution Relay Box The Rear Wiper Down Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 11326 Wiper Relay: Locations Rear Wiper Up Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 11327 Power Distribution Relay Box The Rear Wiper Up Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 11328 Wiper Relay: Locations Wiper High/Low Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 11329 Power Distribution Box The Wiper High-Low Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 11330 Wiper Relay: Locations Wiper Run/Park Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 11331 Power Distribution Box The Wiper Run/Park Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 11336 Windshield Washer Switch: Diagrams Multi_function Switch Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 11337 Windshield Washer Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. The integrated multi-function switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer, rear wiper/washer and hazard warning. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Windshield Washer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11340 Windshield Washer Switch: Diagnostic Trouble Code Descriptions GEM Diagnostic Trouble Code Index Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11341 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11342 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11343 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11344 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11345 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11346 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11347 Windshield Washer Switch: Component Tests and General Diagnostics Multi-Function Switch Component Test Multi-Function Switch - Component Testing Procedure Multi-Function Switch - Terminals Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11348 Multi-Function Switch - Schematic - Wiper/Washer Portion Of Multi-Function Switch Multi-Function Switch Electrical Test 1. Measure the resistance between the multi-function switch terminals. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11349 2. If the resistances are as specified, multi-function switch is OK. RETURN the multi-function switch to the vehicle. TEST the system for normal operation. If the resistances are not as specified. REPLACE the multi-function switch. TEST the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 11350 Windshield Washer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Release the four clips and remove the steering column opening cover. NOTE: Move gear selector to lowest position to access steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 11351 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 11355 Wiper Switch: Diagrams Multi_function Switch Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 11356 Wiper Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. The integrated multi-function switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer, rear wiper/washer and hazard warning. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 11359 Wiper Switch: Pinpoint Tests A1 - A2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 11360 A3 - A4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 11361 B1 - B2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 11362 C1 D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 11363 Wiper Switch: Component Tests and General Diagnostics Multi-Function Switch Component Test Multi-Function Switch - Component Testing Procedure Multi-Function Switch - Terminals Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 11364 Multi-Function Switch - Schematic - Wiper/Washer Portion Of Multi-Function Switch Multi-Function Switch Electrical Test 1. Measure the resistance between the multi-function switch terminals. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 11365 2. If the resistances are as specified, multi-function switch is OK. RETURN the multi-function switch to the vehicle. TEST the system for normal operation. If the resistances are not as specified. REPLACE the multi-function switch. TEST the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 11366 Wiper Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Release the four clips and remove the steering column opening cover. NOTE: Move gear selector to lowest position to access steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 11367 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation Washer Fluid Level Indicator: Description and Operation The low washer fluid indicator chime warns that the washer fluid level is low. The low washer fluid indicator chime is a single tone with a duration of one second. The chime will sound when the low washer fluid indicator is initially activated. The low washer fluid indicator warns that the fluid level in the washer reservoir is low. The low washer fluid indicator will illuminate for 60 seconds and is activated when: ^ The washer fluid level is low and the ignition switch is moved from START to RUN. ^ The washer fluid level is low, the ignition switch is in the RUN position, and the front windshield washer switch or the rear windshield washer switch is activated. The low washer fluid indicator will deactivate when: ^ The fluid level is raised enough to deactivate the washer fluid level switch for at least five seconds. ^ The ignition switch is moved from the RUN position to the START, OFF/LOCK, or ACC position. ^ The low washer fluid indicator has been illuminated for 60 seconds. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation > Page 11371 Washer Fluid Level Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Specifications Windshield Washer Pump: Specifications Windshield Washer Reservoir Screw .............................................................................................................................................. 4.6-5.4 Nm (42-48 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Specifications > Page 11375 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Specifications > Page 11376 Windshield Washer Pump: Service and Repair REMOVAL 1. Disconnect the jack handle from the windshield washer reservoir. 2. Disconnect the electrical connectors. 3. Remove the windshield washer reservoir screws. 4. Disconnect the windshield washer hoses. NOTE: Windshield washer fluid should be collected in a container after the windshield washer hoses are disconnected. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Specifications > Page 11377 5. Remove the windshield washer reservoir. 6. Remove the windshield washer pump. INSTALLATION 1. To install, reverse the removal procedure. Fill the windshield washer reservoir with windshield washer fluid. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay Windshield Washer Relay: Locations Front Washer Pump Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 11382 Power Distribution Box The Front Washer Pump Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 11383 Windshield Washer Relay: Locations Rear Washer Pump Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 11384 Power Distribution Relay Box The Rear Washer Pump Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications Windshield Washer Reservoir: Specifications Windshield Washer Reservoir Screw .............................................................................................................................................. 4.6-5.4 Nm (42-48 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 11388 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 11389 Windshield Washer Reservoir: Service and Repair REMOVAL 1. Disconnect the jack handle from the windshield washer reservoir. 2. Disconnect the electrical connectors. 3. Remove the windshield washer reservoir screws. 4. Disconnect the windshield washer hoses. NOTE: Windshield washer fluid should be collected in a container after the windshield washer hoses are disconnected. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 11390 5. Remove the windshield washer reservoir. 6. Remove the windshield washer pump. INSTALLATION 1. To install, reverse the removal procedure. Fill the windshield washer reservoir with windshield washer fluid. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 11394 Windshield Washer Switch: Diagrams Multi_function Switch Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 11395 Windshield Washer Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. The integrated multi-function switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer, rear wiper/washer and hazard warning. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Windshield Washer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11398 Windshield Washer Switch: Diagnostic Trouble Code Descriptions GEM Diagnostic Trouble Code Index Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11399 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11400 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11401 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11402 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11403 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11404 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11405 Windshield Washer Switch: Component Tests and General Diagnostics Multi-Function Switch Component Test Multi-Function Switch - Component Testing Procedure Multi-Function Switch - Terminals Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11406 Multi-Function Switch - Schematic - Wiper/Washer Portion Of Multi-Function Switch Multi-Function Switch Electrical Test 1. Measure the resistance between the multi-function switch terminals. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11407 2. If the resistances are as specified, multi-function switch is OK. RETURN the multi-function switch to the vehicle. TEST the system for normal operation. If the resistances are not as specified. REPLACE the multi-function switch. TEST the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 11408 Windshield Washer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Release the four clips and remove the steering column opening cover. NOTE: Move gear selector to lowest position to access steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 11409 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Adjustment Wiper Arm: Specifications Adjustment Windshield Wiper Blade and Pivot Arm Adjustment RH Wiper Blade ................................................................................................................................... .......................................... 65-93 mm (2.3-3.7 in) LH Wiper Blade ..................................................... ......................................................................................................................... 45-75 mm (1.7-3.0 in) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Adjustment > Page 11414 Wiper Arm: Specifications Tightening Windshield Wiper Mounting Arm and Pivot Shaft Bolts ...................................................................................................................... 7-9 Nm (63-80 in lb) Windshield Wiper Linkage Bolt .................................................................................................................................................. 14.8-20.2 Nm (11-14 ft lb) Windshield Wiper Pivot Arm Nuts .................................................................................................................................................... 30-40 Nm (23-29 ft lb) Rear Window Wiper Pivot Arm Nut ........................................................................................................................................... 12.7-17.3 Nm (10-12 ft lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 11415 Wiper Arm: Adjustments WINDSHIELD WIPER BLADE AND PIVOT ARM ADJUSTMENT 1. Cycle and park the windshield wipers. 2. Verify the distance between the center of the (A) RH windshield wiper blade and the (C) bottom of the windshield glass is within specification. 3. Verify the distance between the center of the (B) LH windshield wiper blade and the (C) bottom of the windshield glass is within specification. 4. If the distance is not within specification, remove the windshield wiper pivot arms and reposition to specification 1 Remove the two pivot arm nut covers (one each side). 2 Remove the two nuts (one each side). 3 Remove and reposition the windshield wiper pivot arms. 5. Tighten the windshield wiper pivot arm nuts. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 11416 Wiper Arm: Service and Repair REMOVAL NOTE: The windshield wiper pivot arms must be in the highest position to remove. 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 to the OFF position. 4. Remove the windshield wiper pivot arm. 1 Remove the pivot arm nut cover. 2 Remove the nut. 3 Remove the windshield wiper pivot arm. INSTALLATION 1. To install, reverse the removal procedure. ^ Adjust the windshield wiper pivot arms. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications Wiper Motor: Specifications Windshield Wiper Motor Bolts ................................................................................................................................................... 12.7-17.3 Nm (10-12 ft lb) Rear Window Wiper Motor Screws .................................................................................................................................................. 9-12 Nm (80-107 in lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Rear Window Wiper Motor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Rear Window Wiper Motor > Page 11422 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Rear Wiper Motor Rear Wiper Motor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Rear Wiper Motor > Page 11425 Windshield Wiper Motor Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 11426 Wiper Motor: Testing and Inspection WINDSHIELD WIPER MOTOR CURRENT DRAW TEST 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 replacement windshield wiper motors may also damage the motor magnets. Use Alternator, Regulator, Battery and Starter Tester (ARBST) to test the windshield wiper motor on the vehicle. To test the windshield wiper motor, disconnect the windshield wiper mounting arm and pivot shaft from the windshield wiper motor. Disconnect the windshield wiper motor connector. Connect the (A) green lead from (B) Alternator, Regulator, Battery and Starter Tester to the battery negative (-) post. Connect the (C) red lead from the tester to the windshield wiper motor (D) common brush terminal (terminal 3). Test the low speed mode by connecting a (E) cable from the battery positive (+) post to the (F) low speed brush terminal (terminal 4) and measure the current draw. If the current draw is greater than 3.5 amperes, replace the windshield wiper motor. Test the high speed mode by connecting a cable from the battery positive (+) post to the (G) high speed brush terminal (terminal 5) and measure the current draw. If the current draw is greater than 5.5 amperes, replace the windshield wiper motor. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor Wiper Motor: Service and Repair Front Wiper Motor REMOVAL 1. Remove the mounting arm and pivot shaft. 2. Disconnect the windshield wiper linkage. 1 Remove the bolt. 2 Disconnect the windshield wiper linkage. 3. Remove the windshield wiper motor. 1 Remove the bolts. 2 Remove the windshield wiper motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 11429 Wiper Motor: Service and Repair Rear Wiper Motor REMOVAL 1. Remove the rear wiper arm. 1 Remove the cover. 2 Remove the nut. 3 Remove the rear wiper arm. 2. Remove the upper liftgate trim panel. 3. Remove the liftgate assist strap. 1 Remove the screws. 2 Remove the liftgate assist strap. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 11430 4. Remove the lower liftgate trim panel. 5. Remove liftgate watershield. 6. Remove the rear window wiper motor. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the rear window wiper motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications Wiper Motor Linkage: Specifications Windshield Wiper Mounting Arm and Pivot Shaft Bolts ...................................................................................................................... 7-9 Nm (63-80 in lb) Windshield Wiper Linkage Bolt .................................................................................................................................................. 14.8-20.2 Nm (11-14 ft lb) Windshield Wiper Pivot Arm Nuts .................................................................................................................................................... 30-40 Nm (23-29 ft lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications > Page 11434 Wiper Motor Linkage: Service and Repair REMOVAL 1. Remove the cowl top vent panels. 2. Remove the mounting arm and pivot shaft. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the mounting arm and pivot shaft. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Specifications Wiper Pivot: Specifications Windshield Wiper Mounting Arm and Pivot Shaft Bolts ...................................................................................................................... 7-9 Nm (63-80 in lb) Windshield Wiper Linkage Bolt .................................................................................................................................................. 14.8-20.2 Nm (11-14 ft lb) Windshield Wiper Pivot Arm Nuts .................................................................................................................................................... 30-40 Nm (23-29 ft lb) Rear Window Wiper Pivot Arm Nut ........................................................................................................................................... 12.7-17.3 Nm (10-12 ft lb) Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Specifications > Page 11438 Wiper Pivot: Service and Repair REMOVAL 1. Remove the cowl top vent panels. 2. Remove the mounting arm and pivot shaft. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the mounting arm and pivot shaft. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay Wiper Relay: Locations Rear Wiper Down Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 11443 Power Distribution Relay Box The Rear Wiper Down Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 11444 Wiper Relay: Locations Rear Wiper Up Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 11445 Power Distribution Relay Box The Rear Wiper Up Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 11446 Wiper Relay: Locations Wiper High/Low Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 11447 Power Distribution Box The Wiper High-Low Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 11448 Wiper Relay: Locations Wiper Run/Park Relay Engine View Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Down Relay > Page 11449 Power Distribution Box The Wiper Run/Park Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 11453 Wiper Switch: Diagrams Multi_function Switch Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 11454 Wiper Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. The integrated multi-function switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer, rear wiper/washer and hazard warning. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 11457 Wiper Switch: Pinpoint Tests A1 - A2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 11458 A3 - A4 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 11459 B1 - B2 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 11460 C1 D1 Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 11461 Wiper Switch: Component Tests and General Diagnostics Multi-Function Switch Component Test Multi-Function Switch - Component Testing Procedure Multi-Function Switch - Terminals Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 11462 Multi-Function Switch - Schematic - Wiper/Washer Portion Of Multi-Function Switch Multi-Function Switch Electrical Test 1. Measure the resistance between the multi-function switch terminals. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 11463 2. If the resistances are as specified, multi-function switch is OK. RETURN the multi-function switch to the vehicle. TEST the system for normal operation. If the resistances are not as specified. REPLACE the multi-function switch. TEST the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-281 4.6L SOHC (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 11464 Wiper Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Release the four clips and remove the steering column opening cover. NOTE: Move gear selector to lowest position to access steering column opening cover.