REMOVAL AND INSTALLATION Procedure revision date: 05/17/2000

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1 1997 Aerostar/Ranger REMOVAL AND INSTALLATION Procedure revision date: 05/17/2000 Module, Driver Side Air Bag NOTE: In general, if the air bag did not deploy in an accident, it was not needed. Complete all diagnosis procedures before replacing any air bag system component. Removal WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR SYSTEM DEPLOYMENT IS POWERED DIRECTLY FROM THE BATTERY AND BACKUP POWER SUPPLY. TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BATTERY POSITIVE CABLE MUST BE DISCONNECTED FOR ONE MINUTE PRIOR TO SERVICING OR REPLACING ANY SYSTEM COMPONENTS. 1. Disconnect battery positive cable and wait one minute for backup power supply energy to be depleted. 2. Remove four nut and washer assemblies retaining driver side air bag module (043B13) to steering wheel (3600). (1 of 3) [8/8/ :14:14 PM]

2 1997 Aerostar/Ranger 3. Disconnect the electrical connector on driver side air bag module from connector on air bag sliding contact (14A664). 4. WARNING: AFTER REMOVING DRIVER SIDE AIR BAG MODULE, PLACE ON BENCH WITH TRIM COVER FACING UP. Remove driver side air bag module. Installation 1. Fill out the traceability postcard supplied with the new driver side air bag module and return it to Ford Motor Company. Note the diagnostic trouble code. 2. Connect driver side air bag module wiring connector to connector on air bag sliding contact. 3. Position driver side air bag module to steering wheel and secure with four nut and washer assemblies. Tighten to 4-6 Nm (36-53 lb-in). 4. Connect battery positive cable. When the battery has been disconnected and reconnected, some abnormal drive (2 of 3) [8/8/ :14:14 PM]

3 1997 Aerostar/Ranger symptoms may occur while the powertrain control module (PCM) (12A650) 5. Turn ignition switch (11572) to ON position. Allow system to perform self-test. (3 of 3) [8/8/ :14:14 PM]

4 1997 Aerostar/Ranger Steering Wheel CAUTION: Do not remove the steering column, steering wheel (3600) and air bag sliding contact (14A664) as an assembly from the vehicle unless the column is locked to prevent rotation, or lower steering column shaft (3B676) should be wired in such a way to prevent the steering wheel from being rotated. Excessive rotation will damage air bag sliding contact. SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Steering Wheel Puller T67L-3600-A Removal 1. Center wheels (1007) to the straight-ahead position. 2. Disconnect battery ground cable (14301) and air bag backup power supply. Refer to Section 01-20C. 3. WARNING: THE BACKUP POWER SUPPLY MUST BE DISCONNECTED BEFORE ANY AIR BAG COMPONENT IS SERVICED. Remove four air bag module retaining nuts and lift air bag sliding contact off steering wheel. 4. Disconnect air bag wire harness from air bag sliding contact and remove module from wheel. (1 of 3) [8/8/ :15:04 PM]

5 1997 Aerostar/Ranger 5. Disconnect speed control wire harness from steering wheel, if so equipped. 6. Remove steering wheel retaining bolt. 7. Install Steering Wheel Puller T67L-3600-A and remove steering wheel. Route contact assembly wire harness through steering wheel as steering wheel is lifted off shaft. (2 of 3) [8/8/ :15:04 PM]

6 1997 Aerostar/Ranger Installation 1. NOTE: Make sure that wheels are in the straight-ahead position. Route contact assembly wire harness through steering wheel opening at the three o'clock position and position steering wheel on steering shaft. The steering wheel and shaft alignment marks should be aligned. Be sure air bag contact wire is not pinched. 2. CAUTION: Be sure wiring does not get trapped between steering wheel and contact assembly. Install new steering wheel retaining bolt and tighten to Nm (23-33 lb-ft). 3. Connect speed control wire harness to steering wheel and snap connector assembly into steering wheel clip. 4. Connect air bag wire harness to air bag module and install module to steering wheel. Tighten module retaining nuts to 4-6 Nm (35-53 lb-in). 5. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) (12A650) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Connect air bag backup power supply and battery ground cable. Verify air bag warning indicator. (3 of 3) [8/8/ :15:04 PM]

7 1997 Aerostar/Ranger Air Bag Sliding Contact Removal 1. WARNING: THE ELECTRICAL CIRCUIT FOR AIR BAG DEPLOYMENT IS POWERED DIRECTLY FROM THE BATTERY POWER SUPPLY. TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BATTERY POSITIVE CABLE MUST BE DISCONNECTED FOR A MINIMUM OF ONE MINUTE BEFORE BEGINNING WORK TO DE-ENERGIZE THE BACKUP POWER SUPPLY. Make sure that vehicle's front wheels (1007) are in the straight-ahead position and steering column shaft alignment mark is at the 12 o'clock position. 2. Disconnect battery to battery to starter relay cable (14300) for at least one minute to let the air bag backup power supply discharge. 3. Remove steering wheel (3600) as described in this section. 4. CAUTION: Be sure air bag sliding contact internal lock is engaged. Hub should not turn more than 45 degrees in either direction. Remove upper and lower steering column shrouds (3530) as described in this section. 5. Disconnect three air bag sliding contact electrical connectors from main wiring (14401) at steering column bend bracket. 6. Using door trim removal tool, remove air bag sliding contact electrical connectors from bend bracket. 7. CAUTION: Do not remove wire harness clips from wire bundle. Using door trim removal tool, disconnect two wire harness clips from column. 8. Remove key warning buzzer contact and anti-theft contact from ignition lock cylinder pocket of lock cylinder housing. 9. Remove air bag sliding contact (14A664) by pushing snap back at 6 o'clock position (1 of 3) [8/8/ :15:33 PM]

8 1997 Aerostar/Ranger first, then 3 o'clock position, then 12 o'clock position and remove from steering shaft. Installation 1. Make sure that the vehicle's front wheels are straight ahead and steering column shaft alignment mark is at the 12 o'clock position. 2. Align air bag sliding contact to column shaft and mounting tabs and slide onto shaft. Push on air bag sliding contact to snap three tabs onto steering column tube flange. 3. Install air bag sliding contact cable clips into holes in steering column. 4. Install air bag sliding contact connector retainers into provided holes in steering column bend bracket. 5. Plug main wiring harness connectors into three air bag sliding contact connectors. 6. Install key warning buzzer contact and anti-theft contact into ignition lock cylinder pocket in lock cylinder housing. Make sure contacts do not slip out of ignition lock cylinder pocket. (2 of 3) [8/8/ :15:33 PM]

9 1997 Aerostar/Ranger 7. Install upper and lower steering column shrouds as described in this section. 8. Install steering wheel as described in this section. 9. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) (12A650) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Connect battery to starter relay cable. 10. Verify air bag warning indicator operation. (3 of 3) [8/8/ :15:33 PM]

10 SECTION B: Occupant Restraints Passive Supplemental Air Bag System 1998 Ranger Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 03/03/2000 Air Bag Sliding Contact Removal WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. If damaged, the sensor should be replaced whether or not the air bag is deployed. (1 of 8) [8/8/2009 1:54:57 PM]

11 WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any air bag supplemental restraint system (SRS) components. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: A repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Remove the driver air bag module. For additional information, refer to Module Driver Air Bag in this section. 2. NOTE: Make sure the wheels (1007) are in the straight-ahead position. Remove the steering wheel (3600). For additional information, refer to Section If so equipped, twist the tilt wheel handle and shank (3F609) and remove. 4. Remove the lower steering column shroud (3530). 1. Remove the three screws. 2. Remove the steering column shroud. (2 of 8) [8/8/2009 1:54:57 PM]

12 5. Remove the ignition switch lock cylinder (11582). 1. Position the lock cylinder to RUN. 2. Using a suitable tool, push upward on the cylinder release tab through the hole in the lower shroud while pulling the cylinder outward. 6. Carefully pry to release the clips and remove the steering column opening cover. 7. Remove the upper steering column shroud. (3 of 8) [8/8/2009 1:54:57 PM]

13 8. NOTE: The air bag sliding contact (14A664) has a service lock that prevents accidental rotation when the steering wheel is removed. Prevent accidental rotation of the air bag sliding contact. 1. Check to see if the service lock is missing. 2. If the service lock is missing, apply two strips of masking tape across the air bag sliding contact. 9. Remove the key-in-ignition warning indicator switch. (4 of 8) [8/8/2009 1:54:57 PM]

14 10. Disconnect the air bag sliding contact electrical connector and separate the air bag electrical connector from the bracket. 11. Pry the retaining clips loose. 12. Separate the wire from the two retaining clips holding the wire to the column. 13. Remove the air bag sliding contact. Feed the wiring harness through the instrument panel (04320). (5 of 8) [8/8/2009 1:54:57 PM]

15 Installation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. NOTE: The air bag sliding contact has a service lock that prevents rotation of the air bag sliding contact when the steering wheel is removed. If the lock is missing, realign the air bag sliding contact. 1. Rotate the air bag sliding contact rotor counterclockwise until it stops. 2. Rotate two revolutions. 3. Install per instructions. 2. Properly orientate the air bag sliding contact. 1. The air bag electrical pigtail must point to the three o'clock position. 2. The dot on the steering shaft must be at the nine o'clock position. (6 of 8) [8/8/2009 1:54:57 PM]

16 3. Press at the six, twelve and three o'clock positions to seat the air bag sliding contact. 4. Rotate the wiring and secure into two wire clips. 5. Connect the two electrical connectors. Snap into the bracket. 6. Install the key-in-ignition warning indicator switch. 7. If a new clockspring is used, remove the yellow anti-rotation tab. 8. Install the upper steering column shroud. 9. Install the ignition switch lock cylinder. 1. Turn the ignition switch lock cylinder to the RUN position. 2. Insert the ignition switch lock cylinder into the steering column housing. 3. Make sure the ignition switch lock cylinder is fully seated and aligned in the interlocking washer before turning the key to the OFF position. This will permit the retaining pin of the ignition switch lock cylinder to extend into the hole in the steering column. (7 of 8) [8/8/2009 1:54:57 PM]

17 10. Rotate the ignition switch lock cylinder, using the key, to make sure of correct mechanical operation in all positions. 11. Install the lower steering column shroud. 12. Install the steering column opening cover. 13. If so equipped, install the tilt wheel handle and shank. 14. NOTE: Make sure the front wheels are in the straight-ahead position. Install the steering wheel. For additional information, refer to Section Install the driver air bag module. For additional information, refer to Module Driver Air Bag in this section. (8 of 8) [8/8/2009 1:54:57 PM]

18 SECTION : Steering Column 1998 Ranger Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 03/03/2000 Wheel Special Tool(s) 2-Jaw Puller (T77F-4220-B1) Removal WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be (1 of 5) [8/8/2009 1:55:38 PM]

19 replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle shop manual to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. NOTE: Make sure the wheels (1007) are in the straight-ahead position. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to Section Disconnect the battery ground cable (14301) and wait at least one minute. Disconnect the battery to starter relay cable. 2. Remove the driver air bag module. For additional information, refer to Section B. 3. Remove the steering wheel bolt. (2 of 5) [8/8/2009 1:55:38 PM]

20 4. CAUTION: Removing the steering wheel without using a puller can damage the column bearings. Use the 2-Jaw Puller to remove the steering wheel (3600). 5. Remove and discard the original steering wheel bolt. 6. Remove the steering wheel while routing the wires from the air bag sliding contact through the steering wheel. Installation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed (3 of 5) [8/8/2009 1:55:38 PM]

21 away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle shop manual to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). (4 of 5) [8/8/2009 1:55:38 PM]

22 1. Follow the removal procedure in reverse order. 2. Connect the battery cable. For additional information, refer to Section (5 of 5) [8/8/2009 1:55:38 PM]

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