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Rear Door Trim Panel Removal 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. NOTE: Use care not to damage the trim panel when removing the screws. Remove the screws. 3. Remove the handle. 4. Remove the screws. 5. Remove the rear door trim panel. 6. Disconnect the electrical connector. 7. Disconnect the color-coded clips from the bracket. Installation 1. Connect the clips to the pull-strap. The silver retainer clip goes toward the front of the vehicle. The green retainer clip goes toward the rear of the vehicle. 2. Follow the removal procedure in reverse order.

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1. CAUTION: Prior to the removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. For additional information, refer to Module Configuration in this section. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. For additional information, refer to Section 414-00. 2. Remove the driver door trim panel. For additional information, refer to Section 501-01. 3. Remove the components in the order indicated in the following illustration and table. 1. Once the DDM is installed, it is necessary to download the module configuration information from the daignostic tool into the new module. Refer to Module Configuration in this section. Front Door Trim Panel 1. Disconnect the battery. For additional information, refer to Section 414-00. 2. To remove individual components only, carry out the listed steps. Component Door trim panel Garnish molding Speaker cover Applique 3. Remove the components in the order indicated in the following illustration and table. Window regulator control switch panel asembly

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1. Disconnect battery ground cable (14301). Refer to Section 14-01. 2. Remove instrument panel (04320). Refer to Section 01-12. 3.
Remove four A/C electronic blend door actuator retaining screws. 4. Remove A/C electronic blend door actuator. A/C Electronic Blend Door Actuator Installation 1. Insert A/C electronic blend door actuator into A/C air temperature control door (19D842) (manually moving A/C air temperature control door will help engage shaft). 2. Attach A/C electronic blend door actuator with four retaining screws. 3. Install instrument panel. Refer to Section 01-12. 4. Connect battery ground cable. Refer to Section 14-01.

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ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles may exhibit a noise from the rear wheel hub bearings. Previous service procedures required service replacement of the wheel hub bearing assembly, base part (1109). This new service procedure allows replacement at a lower service level of the wheel bearing, base part (1215) to repair the noise condition. ACTION Replace the rear hub bearing and wheel bearing retainer ring. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE HAVE AN ASSISTANT PRESS THE BRAKE PEDAL TO KEEP THE AXLE FROM TURNING. 1. Remove the axle-to-wheel hub retainer nut and washer (Figure 1). Discard the nut. When reinstalling at end of procedure, tighten to 203 lb-ft (275 N•m).Figure 1 – Article 05-25-8 2. Remove the bolt and disconnect the wheel speed sensor (Figure 2). To install, tighten to 71 lb-in (8 N•m).

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1. Vent the air suspension system. WARNING: DO NOT REMOVE AN AIR SPRING UNDER ANY CIRCUMSTANCES WHEN THERE IS PRESSURE IN THE AIR SPRING. DO NOT REMOVE ANY COMPONENTS SUPPORTING AN AIR SPRING WITHOUT EITHER EXHAUSTING THE AIR OR PROVIDING SUPPORT FOR THE AIR SPRING TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY . 2. Turn the air suspension switch off. WARNING: BEFORE PERFORMING MAINTENANCE ON ANY AIR SUSPENSION COMPONENTS, DISCONNECT THE POWER TO THE SYSTEM BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED ON THE LH SIDE OF THE LUGGAGE COMPARTMENT TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY . 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. 6. Remove the air spring. 1) Disconnect the electrical connector. 2) Push up on the air line retaining ring and disconnect the air line. 3) Remove the air spring. INSTALLATION To install, reverse the removal procedure. NOTE: To avoid damage to the air spring, do not allow suspension to compress before the spring is inflated. When installing the air line into the solenoid, a minimum of 3 mm (1/8 inch) of line must be inserted for proper operation of the air spring.