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LINCOLN: 2008-2010 Town Car 2000-2005 Navigator 2007-2009 MKX MERCURY: 2008-2010 Grand Marquis, Mariner Hybrid, Mariner This article supersedes TSB 9-19-16 to update the Service Procedure. ISSUE Some vehicles may experience white flakes coming from the A/C vents when the blower motor is engaged. This may be caused by flux utilized in the manufacturing process of the evaporator core. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Hazard and Risk Warnings for White Flakes WARNING MAY CAUSE EYE AND RESPIRATORY TRACT IRRITATION. PROLONGED REPEATED EXPOSURE MAY CAUSE BONE DAMAGE (FLUOROSIS) AND HARM TO THE RESPIRATORY SYSTEM (BASED ON ANIMAL DATA). ^ Avoid inhaling dust. ^ Avoid contact with eyes. ^ Store away from acids. ^ Wash thoroughly after handling. ^ Avoid release to the environment. NOTE THE USE OF DUST PROOF GOGGLES, CHEMICAL RESISTANT GLOVES (PVC) AND DUST MASK IS RECOMMENDED. Using compressed air (maximum inlet pressure) 100 PSI (689 kPa), clean the A/C ducts through the registers and blow off the evaporator core through the blower motor opening. NOTE THE ENTIRE EVAPORATOR CORE SURFACE MUST BE DRY FOR BEST RESULTS. NOTE WHILE PERFORMING THIS PROCEDURE AND SELECTING DIFFERENT VENT MODES SUCH AS FLOOR / PANEL AND FLOOR / DEFROST, IT MAY BE NECESSARY TO TEMPORARILY START THE ENGINE TO ENABLE MODE DOOR MOVEMENT. Clean A/C Ducts: 1. Remove floor duct trim. 2. Using masking tape, connect one end of the vacuum cleaner hose to the floor duct on driver side. 3. Tape closed all the other floor duct openings. 4. Obtain about two feet (61 cm) of rubber vacuum line large enough to fit the end of a small shop air blowgun. Secure the hose to the end of the blowgun using a worm clamp. 5. Close all instrument panel registers. 6. Set temperature setting to full cold. 7. Place mode in floor / panel. 8. Turn on vacuum cleaner. 9. Working with one register at a time insert the vacuum line down each duct and blow shop air through each duct for 30 seconds. Be sure to close each register before moving on to the next register. 10. Change mode to floor I defrost.

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Removal and Installation 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. For additional information, refer to Component Tests in Section 412-00. NOTE: Installation of a new suction accumulator 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. 1. Recover the refrigerant. For additional information, refer to Section 412-00. 2. Remove the instrument panel. For additional information, refer to Section 501-12. 3. Remove the junction box splash shield, if equipped. 4. Disconnect the cable ends. 5. Remove the junction block bracket. 1. Disconnect the electrical connector. 2. Remove the screws. 3. Detach the pin-type retainers and remove the junction block bracket. 6. Using suitable tools, clamp off the heater core inlet and outlet hoses. 7. Gently push each heater hose towards the heater core, compress the clip, and disconnect the heater hoses from the heater core. For additional information, refer to Section 412-00. 8. Disconnect the refrigerant spring lock couplings from the evaporator inlet and outlet. For additional information, refer to Section 412-00. 9. Remove the screw and the RH demister adapter. 10. Remove the screws and remove the defroster duct and LH demister adapter as an assembly. 11. Remove the nut. 12. Remove the nut. 13. Disconnect the vacuum line from the parking brake release solenoid. 14. Disconnect the vacuum connector from the panel/floor vacuum control motor. 15. Disconnect the vacuum line. 16. Remove the screw. 17. Remove the screw. 18. Remove the nut.

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1. If equipped, remove the floor duct panel. Remove the two plastic push pins (one each side) and release the expander clip. 2. If equipped, remove the floor console. For additional information, refer to Section 501-12 . 3. Remove the RH instrument panel brace. 1. Remove the lower nut. 2. Remove the upper bolt. 3. Remove the brace. 4. Remove the LH instrument panel lower nut and position brace aside. 5. Remove the floor duct. 1. Remove the two screws (one each side). 2. Remove the floor duct. 6. NOTE: Rotate the vacuum control motor to disconnect the vacuum control motor rod from the panel/floor door. Remove the panel/floor door vacuum control motor (18A318). 1. Disconnect the vacuum line connector. 2. Remove the panel/floor door vacuum control motor screws. 3. Slide the rod out to the door and remove the panel/floor door vacuum control motor. 7. Remove the electronic actuator. 1. Disconnect the electronic actuator electrical connector. 2. Remove the three actuator screws. 3. Pull down to release the actuator shaft and remove the electronic actuator.

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ISSUE Some vehicles may experience white flakes coming from the A/C vents when the blower motor is engaged. This may be caused by flux utilized in the manufacturing process of the evaporator core. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Hazard and Risk Warnings for White Flakes WARNING MAY CAUSE EYE AND RESPIRATORY TRACT IRRITATION. PROLONGED REPEATED EXPOSURE MAY CAUSE BONE DAMAGE (FLUOROSIS) AND HARM TO THE RESPIRATORY SYSTEM (BASED ON ANIMAL DATA). • Avoid inhaling dust. • Avoid contact with eyes. • Store away from acids. • Wash thoroughly after handling. • Avoid release to the environment. NOTE THE USE OF DUST PROOF GOGGLES, CHEMICAL RESISTANT GLOVES (PVC) AND DUST MASK IS RECOMMENDED. Clean A/C Ducts: 1. Remove floor duct trim. 2. Using masking tape, connect one end of the vacuum cleaner hose to the floor duct on driver side. 3. Tape closed all the other floor duct openings. 4. Obtain about two feet (61 cm) of rubber vacuum line large enough to fit the end of a small shop air blowgun. Secure the hose to the end of the blowgun using a worm clamp. 5. Close all instrument panel registers. 6. Set temperature setting to full cold. 7. Place mode in floor / panel. 8. Turn on vacuum cleaner.

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1. Vehicle Preparation. (a) Open hood. (b) Place a fender cover over the driver’s side fender to protect the vehicle paint. 2. Check Kit Contents. (a) Check the Front Brake Upgrade kit for contents and damage. 3. Attach Brake Fluid Fill Adaptor. (a) Remove brake reservoir cap. (b) Fix adaptor in place. (1) Route chain all the way under the master cylinder as shown in (Fig. 3-1). (2) Tighten wing nut snug, do not over tighten. (c) Attach the locking vacuum line to the adaptor (Fig. 3-2). (d) Close the air valve on the adaptor. (1) Turn valve clockwise until closed (Fig. 3-3). (e) Press B-1 button then START (Fig. 3-4). (1) After alarm sounds press STOP button NOTE: You may continue to the next step while waiting for the alarm to sound. 4. Remove front wheels (a) Use a vehicle hoist to lift the vehicle using the vehicle jacking points. If a vehicle hoist is not available, use a hydraulic jack to lift the front of the vehicle and set it on jack stands. Use the owner’s manual to locate the proper vehicle jacking points. Caution: Always use jack stands to support the vehicle, never work on a vehicle using only the jack. (b) Use a 22mm deep socket and ½” air impact gun to remove all front wheel lug nuts. (c) Remove both front wheel/tire assemblies and save for reuse. 5. Disconnect & Remove the Front Brake Hose. (a) Place a drip tray directly below the inboard brake line connection. This connection is where the rubber hose attaches to the steel brake line as shown in (Fig. 5-1). Caution: Brake fluid will damage most painted surfaces. Immediately clean any spilled brake fluid from all painted surfaces. (b) Use a 10mm flare nut wrench to loosen the steel line fitting where it attaches to the rubber brake hose (Fig. 5-1). (c) Use a pair of needle-nose pliers to remove the brake line retaining clip (Fig 5-2). Retain this clip for re-use. (d) Repeat steps 5(b) & 5(c) for the connection on the lower end of the rubber brake hose (Fig. 5-3). Remove and discard the rubber brake hose but retain the clip. 6. Remove Factory Brake Caliper, & Rotor. (a) Using a 17mm socket, loosen and remove the two bolts from the original equipment (OE) caliper (Fig. 6-1). Discard these bolts as they will be replaced by longer bolts. (b) Remove and retain the steel brake line from the OE caliper. Discard the OE Caliper. (c) Remove the OE rotor from the hub and discard.