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Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the shift cable from the manual control lever. 3. Disconnect the digital transmission range (TR) sensor electrical connector. 4. Remove the manual control outer lever nut and manual control outer lever. 2004 Ford Truck Ranger 2WD V6-4.0L VIN E 5. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut.

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ENGINE – 4.0L OHV – CARBON KNOCK ON ACCELERATION NOISE – CARBON KNOCK ON ACCELERATION – VEHICLES EQUIPPED WITH 4.0L OHV ENGINE ONLY FORD: 1990-1997 AEROSTAR 1990-2000 EXPLORER, RANGER ISSUE Some vehicles equipped with the 4.0L OHV engine may exhibit an engine noise which may be perceived by the customer as a piston/connecting rod bearing knock. This carbon knock is heard only under load during the drive cycle. Carbon knock is a customer drive duty-cycle phenomenon that cannot be repaired with an engine exchange. This may be caused by carbon build-up within the combustion chamber. ACTION Verify condition. If normal diagnostics fail to correct the condition, de-carbon the combustion chamber to help quiet the carbon knock noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE Use Motorcraft Carburetor Tune-up Cleaner PM-3. Carbon removal: a. Disconnect canister purge line from throttle body. b. Attach a vacuum line to the canister purge port. c. At hot engine idle, allow the engine to ingest 1/2 to 2/3 of a can of Motorcraft Carburetor Tune-up Cleaner. Use caution not to ingest too quickly due to potential hydro-lock issues. d Shut engine off and allow it to soak for one hour. e. Start engine, allow engine to ingest the remainder of the Motorcraft Carburetor Tune-up Gleaner. f. Remove vacuum line and re-install canister purge line. g. Road test vehicle at 3500 RPM for 2-3 miles. h. Repeat above procedure two times for a total of three times. i. Change oil and filter.

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1. Loosen the air cleaner outlet tube clamp at the Mass Air Flow (MAF) sensor and remove tube. 2. Disconnect the MAF sensor electrical connector. 3. Remove the engine air cleaner cover. 1 Unclip the two bail clamps. 2 Remove the engine air cleaner cover. 4. Remove the Air Cleaner element (ACL element). 1998 Ford Truck Explorer 2WD V6-245 4.0L VIN X SFI 5. Remove the lower air cleaner assembly. INSTALLATION 1. Follow the removal procedure in reverse order.

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1. Remove the sail panel. NOTE: Release the top portion first. 2. Remove the window regulator switch plate. 3. Disconnect the electrical connectors. 4. Remove the top door trim panel screw. 2001 Ford Truck Expedition 2WD V8-4.6L SOHC VIN W 5. Remove the door trim panel screw at the window regulator switch plate opening. 6. Remove the door trim panel screw in the courtesy lamp housing. 1 Remove the courtesy lamp lens. 2 Remove the screw. 7. Release the inside door handle trim cover. ^ Pull the inside door handle outward. ^ Release the trim cover. 8. Remove the inside door handle. ^ Remove the bolt.9. Lift upward and then outward to remove the front door trim panel. CAUTION: To avoid damage to the front door trim panel, do not pull directly outward. 10. Remove the courtesy lamp. ^ Turn the courtesy lamp bulb socket one-quarter of a turn and remove. 11. Disconnect the power mirror electrical connector. INSTALLATION

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FORD: 2000-2004 Mustang 2000-2005 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2004 Ranger 2000-2005 E-Series, Excursion, Expedition, Explorer, F-150, F-Super Duty 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 2005 Escape Hybrid 2004-2005 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2005 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Grand Marquis, Sable, Mountaineer 2004-2005 Monterey 2005 Mariner ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20a for additional information. NOTE IF TEFLON TAPE IS ALREADY PRESENT ON THE SAFETY BELT GUIDE RING (D-RING), DO NOT CONTINUE WITH THIS TSB. NOTE EACH KIT SERVICES TWO (2) BELTS. NOTE DOES NOT APPLY TO AVIATOR/EXPLORER 4DR/MOUNTAINEER FRONT SAFETY BELTS FOR VEHICLES BUILT AFTER 6/25/2004, OR REAR SAFETY BELTS FOR VEHICLES BUILT AFTER 10/22/2004, BECAUSE TEFLON TAPE IS INSTALLED DURING PRODUCTION.