1995 Mercury Grand Marquis GS

Size: px

Start display at page:

Download "1995 Mercury Grand Marquis GS"

Florence Fisher
6 years ago
Views:

1 AIR BAG SYSTEM CAUTION: Read the following safety precautions BEFORE servicing steering columns on vehicles equipped with air bag restraint system. ALWAYS wear safety glasses when servicing vehicle with air bag and when handling air bag. Air bag system MUST be disabled BEFORE servicing ANY air bag component. See DISABLING & ACTIVATING AIR BAG SYSTEM. When handling air bag module, ensure bag and trim cover are pointed away from your body. This reduces chance of injury in case of accidental air bag deployment. When placing air bag module on bench or other surface, ALWAYS face air bag and trim cover up, away from surface. This reduces motion of module if accidentally deployed. Safety precautions must also be observed when handling a deployed air bag. After deployment, air bag surface may contain deposits of sodium hydroxide, a product of inflation gas generant combustion that irritates skin. ALWAYS wear gloves and safety glasses when handling air bag. Wash hands with mild soap and water afterward. NEVER probe connectors on air bag module. Air bag may deploy causing personal injury. DO NOT attempt to service air bag module or contact assembly. To correct system malfunctions, replace complete assembly. After any servicing, ensure AIR BAG light does not indicate any faults. CONTACT ASSEMBLY (CLOCKSPRING) On vehicles with air bag, the contact assembly contains a clockspring, providing a constant path for electrical current between air bag module and air bag system control devices. Clockspring function is similar to horn slip ring and brush assembly, but provides a more positive connection. Clockspring will be damaged if steering shaft is allowed to rotate after steering shaft has been disconnected from intermediate shaft. When disconnecting steering shaft from intermediate shaft, wire steering shaft to column to prevent clockspring damage. If reusing original contact assembly, tape clockspring rotor in stationary position before removing contact assembly from steering column. See Fig. 1. A locking insert is installed in replacement contact assembly to prevent rotation of clockspring. DO NOT remove locking insert until contact assembly is installed on steering column. For more information on air bag system, see AIR BAG RESTRAINT SYSTEM article listed below: AIR BAG RESTRAINT SYSTEM - Crown Victoria and Grand Marquis AIR BAG RESTRAINT SYSTEM - Town Car Friday, February 27, :22:34 12:22:39 PM Page Mitchell Repair Information Company, LLC.

2 Fig. 1: Taping Contact Assembly Courtesy of FORD MOTOR CO. DISABLING & ACTIVATING AIR BAG SYSTEM CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION section before disconnecting battery. WARNING: If vehicle equipped with passenger-side air bag, BOTH driver-side and passenger-side air bag modules MUST be disabled. DISABLING SYSTEM Friday, February 27, :22:34 PM Page Mitchell Repair Information Company, LLC.

3 1. Disconnect negative battery cable. Disconnect positive battery cable. Wait one minute. This is the time required for back-up power supply in diagnostic monitor to deplete its stored energy. 2. Remove 4 nut assemblies retaining driver-side air bag to steering wheel. Disconnect driver-side air bag module connector. Attach Air Bag Simulator (Rotunda ) to air bag connector to simulate air bag. 3. To disable passenger-side air bag, if equipped, remove instrument panel lower right molding. On Crown Victoria, remove right instrument cluster finish panel. On Grand Marquis, remove right register trim and instrument cluster finish panel. 4. On all models, open glove box door, press glove box sides inward and remove glove box. Through glove box opening, remove 2 front and 2 rear passenger-side air bag module bolts. Disconnect passenger-side air bag connector. 5. Carefully remove air bag module and place it on bench, trim cover facing up. Attach simulator to air bag terminals on wiring harness side of passenger-side air bag module connector (if equipped). If testing or vehicle operation is required, connect positive battery cable, then connect negative battery cable. ACTIVATING SYSTEM 1. Ensure BOTH battery cables are disconnected. Wait one minute. Remove air bag simulator(s) from driver-side air bag and passenger-side air bag wiring harness connector (if equipped). 2. Reconnect driver-side air bag connector to air bag module. Install driver-side air bag module on steering wheel. Tighten nut and washer assemblies to specification. See TORQUE SPECIFICATIONS. 3. Reconnect passenger-side air bag connector to air bag module (if equipped). Install passenger-side air bag module. Tighten bolts to specification. Install trim panels as necessary. Connect positive battery cable, then connect negative battery cable. Check AIR BAG light for system faults. REMOVAL & INSTALLATION CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION section before disconnecting battery. CONTACT ASSEMBLY (CLOCKSPRING) R & I CAUTION: BEFORE servicing any air bag component, see SAFETY PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM. Removal 1. Disconnect negative battery cable. Disconnect positive battery cable. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM. Ensure steering wheel is in straight-ahead position. Mark steering shaft at 12-o'clock position for installation reference. Remove steering wheel. See STEERING WHEEL & HORN PAD. Friday, February 27, :22:34 PM Page Mitchell Repair Information Company, LLC.

4 2. Remove lower moldings from instrument panel by unsnapping from retainer. Remove lower trim panel from instrument panel. Remove lower shroud. See Fig. 2. Disconnect clockspring electrical connector from column harness. 3. If contact assembly is to be re-used, tape contact assembly to prevent rotation of contact assembly. If contact is rotated, clockspring could be damaged internally. See Fig. 1. Remove contact assembly. Installation 1. Ensure front wheels are in straight-ahead position. Ensure steering shaft alignment mark is at 12-o'clock position. Install contact assembly. 2. If installing original contact assembly, remove tape from contact assembly. If installing NEW contact assembly, remove plastic locking insert. 3. Install lower shroud and lower trim panel to instrument panel. Install lower moldings to instrument panel. Connect battery cables. Check AIR BAG light for system faults. Friday, February 27, :22:34 PM Page Mitchell Repair Information Company, LLC.

5 Fig. 2: Exploded View Of Tilt Steering Column (Column Shift) Courtesy of FORD MOTOR CO. STEERING WHEEL & HORN PAD NOTE: On vehicles equipped with air bags, see DISABLING & ACTIVATING AIR BAG Friday, February 27, :22:34 PM Page Mitchell Repair Information Company, LLC.

6 SYSTEM before removing steering wheel. CAUTION: DO NOT strike steering shaft with hammer or use slide hammer to remove steering wheel. Steering shaft bearings could be damaged if appropriate puller is not used to remove steering wheel. Removal 1. Ensure front wheels are in straight-ahead position. Disconnect negative battery cable. Disconnect positive battery cable. Disable air bag system. 2. Remove air bag module retaining nuts or screws from steering wheel. See Fig. 2. Lift air bag module from steering wheel and disconnect clockspring electrical connector from module. 3. Disconnect cruise control switch electrical connector from contact assembly electrical connector. Remove steering wheel bolt. 4. Using Steering Wheel Puller (T67L-3600-A), remove steering wheel. As wheel is removed, route contact assembly and cruise control/horn wiring harnesses through steering wheel. Installation 1. Ensure front wheels are in straight-ahead position. Route contact assembly and cruise control/horn wiring harnesses through steering wheel opening at 3 o'clock position. Position steering wheel onto steering shaft, ensuring steering wheel and shaft alignment marks are aligned. Install NEW steering wheel bolt. Tighten bolt to specification. See TORQUE SPECIFICATIONS. 2. Connect cruise control/horn switch electrical connector. Connect clockspring electrical connector to air bag module and install module. Connect positive battery cable. Connect negative battery cable. Check AIR BAG light for system faults. MULTIFUNCTION SWITCH NOTE: Multifunction switch incorporates turn signal, wiper/washer (most models), hazard warning, flash-to-pass and dimmer switch functions. Removal & Installation 1. Disconnect negative battery cable. Disconnect positive battery cable. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM. Adjust steering wheel to lowest position and remove tilt lever. See Fig. 2. Remove lock cylinder. See LOCK CYLINDER (FUNCTIONAL) or LOCK CYLINDER (NON-FUNCTIONAL). 2. Remove upper and lower shrouds. Remove multifunction switch from housing. Remove wiring harness retainer and disconnect electrical connectors from multifunction switch. To install, reverse removal procedure. IGNITION SWITCH Removal Friday, February 27, :22:34 PM Page Mitchell Repair Information Company, LLC.

7 Disconnect negative battery cable. Disconnect positive battery cable. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM. Remove upper and lower shroud(s). See Fig. 2. Remove tilt lever (if equipped). Disconnect ignition switch electrical connector. Turn lock cylinder to RUN position. Remove ignition switch mounting screws. Remove switch. Installation 1. Ensure pin slot in ignition switch is in RUN position. Turn lock cylinder to START position and release. This sets lock cylinder and actuator pin in RUN position. 2. Install ignition switch. Ensure actuator pin engagement is in switch slot. Connect ignition switch electrical connector. Install tilt lever (if equipped). Connect battery cables. Test ignition switch operation. Install steering column shroud and trim cover. LOCK CYLINDER (FUNCTIONAL) NOTE: If lock cylinder is non-functional (lock cylinder cannot be rotated due to missing key or damaged lock cylinder), see LOCK CYLINDER (NON-FUNCTIONAL). Removal 1. Disconnect negative battery cable. Disconnect positive battery cable. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Remove column end shroud by unsnapping shroud from retaining clip at 9 o'clock position of shroud. See Fig Disconnect key warning switch electrical connector. 4. Turn lock cylinder to RUN position. Locate small hole in casting below lock cylinder. Insert a 1/8" drill bit or punch into hole. Press lock cylinder retaining pin while pulling lock cylinder out of housing. Installation Turn lock cylinder to RUN position. Press retaining pin and insert lock cylinder into housing. Ensure lock cylinder is fully seated and aligned with interlocking washer. Turn lock cylinder to OFF position. This permits retaining pin to extend into hole in housing. Check lock cylinder operation. To complete installation, reverse removal procedure. LOCK CYLINDER (NON-FUNCTIONAL) NOTE: If lock cylinder is functional (key is available and lock cylinder turns freely), see LOCK CYLINDER (FUNCTIONAL). Removal 1. Disconnect negative battery cable. Disconnect positive battery cable. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM. Remove steering wheel. See STEERING WHEEL & HORN PAD. See Fig. 2. Remove upper and lower column shrouds. Disconnect electrical Friday, February 27, :22:34 PM Page Mitchell Repair Information Company, LLC.

8 connector from key warning switch. 2. Using channel lock pliers, twist lock cylinder cap until it separates from lock cylinder. Using a 3/8" (9.5 mm) drill bit, drill down middle of ignition lock key slot about 1 3/4" inch (44 mm) until lock cylinder breaks loose from base of lock cylinder. 3. Remove retainer, washer, ignition switch and actuator. Remove shavings from column housing. Replace column housing if damaged. Installation 1. Install lock cylinder gear, washer and retainer into lock cylinder bore in column housing. Ensure ignition switch is in RUN position by rotating lock cylinder gear fully clockwise to START position, then releasing. Ensure lock cylinder gear keyway is correctly aligned with slot in ignition switch shaft. 2. Turn NEW lock cylinder to RUN position. Press lock cylinder retaining pin located on bottom of lock cylinder. Install lock cylinder. Ensure lock cylinder is fully seated and aligned in interlocking washer. 3. Turn lock cylinder to OFF position to release retaining pin into hole in column housing. Connect electrical connectors to key warning switch and ignition switch. Install upper and lower column shrouds. Install steering wheel. Connect battery cables. Check AIR BAG light for system faults. LOCK CYLINDER GEAR Removal & Installation 1. With lock cylinder removed, carefully note position of retainer in lock cylinder bore. Using a screwdriver with a 90-degree bend on tip, insert tip between retainer and washer. Pull retainer out of lock cylinder bore. 2. Insert screwdriver into double "D" slot of washer and rotate 90 degrees. Remove washer. Carefully note relation of lock cylinder gear to teeth position on lock actuator assembly. Last tooth of lock cylinder gear should be meshed with last tooth on lock actuator assembly. Remove lock cylinder gear. To install, reverse removal procedure. LOCK CYLINDER HOUSING Removal & Installation See STEERING COLUMN OVERHAUL. STEERING COLUMN R & I Removal & Installation 1. Disconnect negative battery cable. Disconnect positive battery cable. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM. Remove steering wheel. See STEERING WHEEL & HORN PAD. CAUTION: Before removing contact assembly (clockspring), see CONTACT ASSEMBLY (CLOCKSPRING) R & I. Friday, February 27, :22:34 PM Page Mitchell Repair Information Company, LLC.

9 2. Remove contact assembly. Remove lower trim cover from instrument panel. Remove right and left lower moldings from instrument panel by unsnapping from retainer. Remove contact assembly. Unscrew and remove tilt release lever from column. See Fig Rotate lock cylinder to RUN position. Insert a 1/8" drill bit or punch into hole in lower shroud below lock cylinder. Press lock cylinder retaining pin with drill bit or punch while pulling lock cylinder out of housing. 4. Remove upper and lower shrouds. Remove instrument panel reinforcement brace under column. 5. On vehicles with column shift, disconnect shift indicator cable from lock cylinder housing by removing 2 retaining screws. Disconnect shift-indicator cable loop from hook on shift control assembly. On vehicles with console shift, remove interlock cable from steering column. 6. On all models, disconnect multifunction switch and ignition switch electrical connectors. Remove multifunction switch. Remove parking brake vacuum release switch. 7. Remove lower pinch bolt from "U" joint connecting steering shaft to intermediate shaft. Disconnect shift cable from pivot on shift selector lever. Remove shift cable and bracket from lower column mounting bracket. 8. While supporting steering column, remove 4 steering column mounting nuts. Remove steering column from vehicle. To install, reverse removal procedure. Check AIR BAG light for system faults. SHAFT BEARINGS NOTE: Shaft bearing removal and installation procedures are not available. OVERHAUL STEERING COLUMN OVERHAUL Disassembly CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION section before disconnecting battery. CAUTION: On models with Supplemental Restraint System (SRS), observe SAFETY PRECAUTIONS. The air bag system is powered directly from the battery through a fused circuit, and a back-up power supply is incorporated into the diagnostic monitor. Air bag system must be disabled before servicing ANY steering column component. See DISABLING & ACTIVATING AIR BAG SYSTEM. 1. Disconnect negative battery cable. Disconnect positive battery cable. Remove steering wheel. See STEERING WHEEL & HORN PAD under REMOVAL & INSTALLATION. Friday, February 27, :22:34 PM Page Mitchell Repair Information Company, LLC.

10 2. Remove contact assembly (clockspring). See CONTACT ASSEMBLY (CLOCKSPRING) R & I. Remove steering column. See STEERING COLUMN R & I. 3. Remove "U" joint, lower coil spring, sensor ring and tolerance ring from lower end of steering shaft. See Fig. 2. Note installation position of turn-signal cancel cam and remove from steering shaft. 4. Remove ignition switch. Remove upper snap ring. Remove upper coil spring and upper tolerance ring. On vehicles with column shift, remove shift control assembly. Remove shift cable bracket. 5. On all models, use a punch to tap loose pivot pin securing lock actuator cam to lock actuator housing. Remove pivot pin with diagonal pliers. Remove bearing retainer from lock cylinder bore. Remove ignition lock gear. Remove 2 tilt pivot bolts. Remove lock cylinder housing from lock actuator housing. 6. Remove steering shaft from column housing. Remove column lock actuator. Using a punch, remove pivot pin from tilt position levers. Remove tilt position lock arms and springs. Reassembly CAUTION: Lock cylinder housing is under spring pressure. To prevent rapid expansion of tilt position spring, hold lock cylinder housing stationary while removing tilt pivot pins. 1. Install steering shaft into lock actuator housing. Install lower column mounting bracket and lower bearing retainer to lock actuator housing. Install lower tolerance ring, sensor ring, lower coil spring and "U" joint to lower end of steering shaft. 2. Position lock actuator assembly into lock actuator housing. Position lock actuator cam in lock actuator housing, and install cam pivot pin with small hammer until flush with lock actuator housing. 3. Using a punch to hold lever in place, install tilt position lever and spring into lock actuator housing. Install other tilt position lever and spring into lock actuator housing. Tap pivot pin into place while driving out drift. 4. Support area of lock actuator housing where tilt position levers are attached by placing lock actuator housing over a partially open vise. Drive in pivot pin until even with housing. Place 2 nuts or spacers between tilt position levers and lock actuator housing so levers are held partially open. 5. Place tilt position spring on lock cylinder housing. Apply multipurpose lubricant to shoulders of tilt pivot bolts. Install lock cylinder housing to lock actuator housing using tilt pivot bolts. 6. Install upper tolerance ring, upper coil spring and a NEW snap ring onto steering shaft. To ease installation of snap ring, place a piece of pipe, 3/4" x 2 1/4" (19 mm x 57 mm), over steering shaft. 7. Insert steering wheel bolt through large washer. Thread steering wheel bolt into steering shaft and tighten until snap ring snaps into groove on steering shaft. Remove bolt and pipe. 8. Install turn signal cancel cam. Align ignition switch pin with slot in lock cylinder housing, and install ignition switch. Apply multipurpose grease to lock cylinder gear and washer. Install lock cylinder gear, washer and retainer into bore of lock cylinder housing. 9. On vehicles with column shift, coat shift control assembly bushings with multipurpose grease and install shift control assembly. Install shift cable bracket onto lower bearing retainer. 10. Install slip ring brush assembly. Install steering column. Install contact assembly (clockspring) and steering wheel. Connect battery cables. Check AIR BAG light for system faults. Friday, February 27, :22:34 PM Page Mitchell Repair Information Company, LLC.

11 TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Flexible Coupling Nut (27-50) Intermediate Shaft-To-"U" Joint Pinch Bolt (18-27) Lock Cylinder Housing Bolt (16-28) Pinion Shaft-To-"U" Joint Pinch Bolt (41-49) Steering Column-To-"U" Joint Pinch Bolt (41-57) Steering Wheel Bolt (31-45) INCH Lbs. (N.m) Air Bag Contact Assembly Screw (2-3) Air Bag Module Bolt (Driver) (4-6) Air Bag Module Bolt (Passenger) Front ( ) Rear ( ) Air Bag Module Nuts ( ) Instrument Panel Bolster Screw ( ) Multifunction Switch Screws (2-3) Steering Column Cover Screws ( ) Friday, February 27, :22:34 PM Page Mitchell Repair Information Company, LLC.

1994 Ford Pickup F250. STEERING COLUMN - EXCEPT STRIPPED CHASSIS 1994 STEERING Ford Motor Co. - Steering Columns - Except Stripped Chassis

1994 Ford Pickup F250. STEERING COLUMN - EXCEPT STRIPPED CHASSIS 1994 STEERING Ford Motor Co. - Steering Columns - Except Stripped Chassis STEERING COLUMN - EXCEPT STRIPPED CHASSIS 1994 STEERING Ford Motor Co. - Steering Columns - Except DESCRIPTION NOTE: Unless otherwise specified, references to Pickup include the F350 Super Duty commercial