2009 Ford F-150 Smart Junction Box (SJB) REMOVAL AND INSTALLATION

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Filed Under (Ford) by admin on 06-03-2011

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Removal NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage to the module may result. NOTE: Prior to the replacement of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new Smart Junction Box (SJB) after installation. For additional information, refer to Section 418-01 to carry out Programmable Module Installation (PMI). NOTE: For the SJB to accept the PMI procedure, the following conditions must be met: The headlamp switch must be in the OFF position (must not be in the AUTOLAMP position, if equipped) The key must be in the ON position The driver door must be open The doors must be unlocked electronically by pressing the door lock control switch to the UNLOCK position momentarily Failure to follow this procedure will result in the PMI procedure to fail. NOTE: The Tire Pressure Monitoring System (TPMS) functionality is integral to the SJB. NOTE: A new SJB is delivered in a “manufacturing mode” with 7 pre-set DTCs. A successful configuration of the SJB, then a successful TPMS sensor training, then a successful self-test including the clearing of all DTCs is required in order to clear the 7 pre-set manufacturing mode DTCs. The 7 manufacturing mode DTCs are: B106D (Tire Pressure Monitor System [TPMS] Initiators Not Configured) This DTC is present when the SJB is not configured, even on applications that are not equipped with initiators. B2477 (Module Configuration Failure) B2868 (Left Front Tire Pressure Sensor Fault) B2869 (Right Front Tire Pressure Sensor Fault) B2870 (Right Rear Tire Pressure Sensor Fault) B2871 (Left Rear Tire Pressure Sensor Fault) C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is only necessary if the SJB is being replaced. Upload the module configuration information from the SJB into the scan tool. For additional information, refer to Section 418-01. 2. Turn the key to the OFF position. 3. Remove the RH cowl panel side trim. 4. Disconnect the 7 electrical connectors. 5. Remove the 2 bolts and the SJB. Installation 1. Position the SJB and install the 2 bolts. Tighten the bolts to 2 Nm (18 lb-in). 2. Connect the 7 SJB electrical connectors. 3. NOTE: If the SJB is not being replaced, this is the last step that is necessary.

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1994 Ford Mustang A/C Evaporator Housing Removal and Installation

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Filed Under (Ford) by admin on 06-03-2011

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1. Disconnect battery ground cable (14301) . 2. Remove two console armrest mounting access covers (047A62) at rear of console panel (045A36) (snaps out) to gain access to armrest retaining bolts. 3. Remove four armrest-to-floor bracket retaining bolts and remove armrest assembly (snaps out of console). 4. Remove console panel gear shift plate (044G24) (snaps out). On vehicles equipped with manual transmissions, shift boot is attached to bottom of finish panel. Remove shift knob and slide boot and console panel gear shift plate up shift lever to remove. 5. To remove top finish panel position emergency brake lever in the UP position. Remove four retaining screws and lift top finish panel up. Disconnect necessary wire connectors. 6. Remove two console-to-rear floor bracket retaining screws. 7. Insert a small screwdriver into two notches at bottom of front upper finish panel and snap out. 8. If the vehicle has a radio chassis (18806) , the radio chassis must be removed. Refer to Section 15-01. If the vehicle doesn’t have a radio chassis , use a small screwdriver and pry radio cover finish panel out of console. 9. Flex glove compartment bin tabs inward. Drop down glove compartment (06010) assembly. Remove two console-to-instrument panel retaining screws. 10. Remove four console bracket retaining screws. Remove console panel from vehicle. 11. Remove three bolts retaining steering column opening cover (3A673) and reinforcement panel. Remove cover. 12. Remove steering column opening reinforcement by removing two bolts. 13. Remove two bolts retaining steering column opening reinforcement and remove reinforcement. 14. Remove six steering column retaining nuts (two retaining the hood release mechanism and four retaining column to lower brake pedal support). Lower steering column to floor. 15. Remove upper and lower steering column shrouds (3530) and disconnect wiring from turn signal and windshield wiper switch (13K359) . 16. Remove steering column through bolt and nut on engine compartment side of cowl panel. Remove steering column from vehicle. 17. Remove brake pedal support nut. 18. Snap out instrument panel defroster opening grille (044E82) . 19. Remove screws from speaker covers. Snap out speaker covers. 20. Remove front screws retaining RH and LH scuff plates at cowl side trim panels. 21. Remove RH and LH cowl side trim panels. 22. Disconnect wiring at RH cowl side. 23. Remove cowl side retaining bolts (one each side). 24. Remove five cowl top screws attachments. 25. Gently pull instrument panel (04320) away from RH side of cowl panel. Disconnect speedometer cable, air conditioning controls and wire connectors. 26. Place a drain pan or suitable container under the heater water hose connections at the cowl panel. 27. Disconnect heater water hoses (18472) from heater core tubes and plug heater water hoses with suitable 5/8-inch and 3/4-inch plugs. Cap heater core tubes to prevent coolant loss from heater core (18476) during removal of heater case. 28. Remove screw retaining A/C evaporator case support bracket (19A639) to cowl top panel. 29. Disconnect vacuum supply supply hose (black) from A/C vacuum supply in engine compartment. 30. Working under the hood (16612) , remove nut retaining heater case to cowl panel. 31. Inside passenger compartment, remove screw retaining A/C evaporator case mounting bracket (19A865) to cowl top panel. 32. Remove one screw retaining A/C evaporator case mounting bracket below heater case to cowl panel. 33. Carefully pull heater case from cowl panel and remove heater case assembly from vehicle. 34. To install, reverse Removal procedure. Check operation of all components. 35. After repairs have been completed, check the coolant level in the radiator (8005) and in the radiator coolant recovery reservoir (8A080) . Fill as required with the recommended coolant mixture.

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2001 Ford Explorer Trim Panel Liftgate Door REMOVAL AND INSTALLATION

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Filed Under (Ford) by admin on 06-03-2011

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Removal 1. Remove the (A) liftgate handle to liftgate screws and the (B) liftgate handle. 2. Remove the liftgate trim panel screw access plug. 3. Remove the screw. 4. Remove the liftgate door trim panel. 1. Use Windshield and Molding/Trim Removal Kit to remove the liftgate door trim panel from the liftgate window opening. 2. Push the liftgate door trim panel toward the top of the liftgate and remove the liftgate trim panel. Installation 1. To install, reverse the removal procedure.

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1998 Ford Windstar A/C Evaporator Housing Assembly REMOVAL AND INSTALLATION

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Filed Under (Ford) by admin on 06-03-2011

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NOTE: Replacement of the suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. Removal 1. Disconnect battery ground cable (14301). Refer to Section 14-01. 2. Remove A/C air inlet duct (19A618) as described. 3. Drain radiator (8005) and disconnect heater water hose (18472) at the heater core (18476) in the engine compartment. Refer to Section 03-03. 4. Remove ground strap attachment (if present) from heater core tube. 5. Discharge A/C system. Refer to System Discharging and Recovery in Section 12-00. 6. Disconnect the refrigerant lines at the A/C evaporator core in the engine compartment using Spring Lock Coupling Tools 412-027 (T81P-19623-G2) (1/2 inch) and 412-040 (T85L-19623-A) (3/4 inch). Cap tubes to prevent entrance of dirt and moisture. 7. Remove heater outlet floor duct (18C433) as described. 8. Remove instrument panel (04320). Refer to Section 01-12. 9. Disconnect electrical harness connectors from heater blower motor switch resistor (18591) , blower motor (18527) and A/C electronic door actuator motor (19E616) . 10. Disconnect wiring harness retainers from A/C evaporator housing (19850). 11. Remove nut and bolt from the support bracket at left side of A/C evaporator housing . 12. Remove four nuts retaining A/C evaporator housing which are located in the engine compartment. 13. Remove A/C evaporator housing assembly. A/C Evaporator Housing Retaining Nut Locations

2004 Ford F-150 Cowl Panel Grille REMOVAL AND INSTALLATION

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Filed Under (Ford) by admin on 06-03-2011

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CAUTION: The cowl grille panels are secured to the cowl with molded hooks. Prying or pulling straight up on the cowl grille panels will break the hooks. If the hooks are damaged or broken, a new cowl grille panel must be installed. 1. Remove the parts in the order indicated in the following illustration and table. 2. To install, reverse the removal procedure. Item 2: Pin-Type Fastener Removal Note 1. Open the hood. Item 3: Left Cowl Grille Panel Removal Note 1. CAUTION: To avoid breaking the retaining hooks on the cowl grill panel, do not pull up on the rear of the cowl grille panel. Release the front edge of the left cowl grille panel. Starting at the center of the vehicle, depress the forward tab and press upward on the front edge of the cowl grille panel to release it from the cowl. 2. Continuing out from the center of the vehicle, depress the remaining forward tabs, and release rest of the front edge of the cowl grille panel from the cowl. 3. Release the four retaining hooks. Starting at the left fender, press down to release the outer retaining hook, then lightly pull up on the front edge of the cowl grille panel. 4. Continuing in toward the center of the vehicle, release the remaining hooks. Item 7: Right Cowl Grille Panel Removal Note NOTE: Remove the left cowl grille panel before attempting to remove the right cowl grille panel. 1. CAUTION: To avoid breaking the retaining hooks on the cowl grille panel, do not pull up on the rear of the cowl grille panel. Release the front edge of the right cowl grille panel. Starting at the center of the vehicle, depress the forward tab and press upward on the front edge of the cowl grille panel to release it from the cowl. 2. Continuing out from the center of the vehicle, depress the remaining forward tabs, and release rest of the front edge of the cowl grille panel from the cowl. 3. Release the four retaining hooks. Starting at the right fender, press down to release the outer retaining hook, then lightly pull up on the front edge of the cowl grille panel. 4. Continuing in toward the center of the vehicle, release the remaining hooks.

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