2002 Explorer Sport/Sport-Trac Workshop Manual
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1 Page 1 of 18 SECTION : Instrument Panel and Console REMOVAL AND INSTALLATION 2002 Explorer Sport/Sport-Trac Workshop Manual Instrument Panel Removal All vehicles CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Remove the driver air bag module. For additional information, refer to Section B. 2. Remove the screws and position the parking brake release handle aside. 3. Remove the screws and position the hood release handle aside. 4. Remove the instrument panel steering column cover. 1. Remove the screws. 2. Remove the instrument panel steering column cover.
2 Page 2 of Remove the instrument panel steering column opening cover reinforcement. 1. Remove the bolts. 2. Remove the instrument panel steering column opening cover reinforcement. 6. If equipped, disconnect the shift cable from the steering column. 1. Disconnect the shift cable from the steering column shift tube lever. 2. Disconnect the shift cable from the steering column bracket. 7. Disconnect the upper intermediate steering shaft from the steering column shaft. 1. Remove and discard the steering column shaft pinch bolt. 2. Slide the intermediate shaft yoke from the steering column shaft.
3 Page 3 of Disconnect the brake pedal position (BPP) switch electrical connector. 9. If equipped, disconnect the clutch pedal position (CPP) switch electrical connector. 10. Remove the two A-pillar lower trim panels. 11. Disconnect the electrical connectors and the ground wires on the passenger side cowl panel.
4 Page 4 of Disconnect the battery junction box (BJB) from the bracket and position aside. 13. Disconnect the bulkhead wiring harness connectors from inside the engine compartment. 1. Loosen the bolts. 2. Disconnect the electrical connectors. 14. Remove the bulkhead connector insulator. 15. Unclip the bulkhead electrical connectors from the dash panel.
5 Page 5 of Remove the passenger air bag module. For additional information, refer to Section B. 17. Disconnect the blend door actuator electrical connector. 18. Disconnect the climate control vacuum harness connector. 19. Disconnect the antenna cable in-line connector.
6 Page 6 of Raise the glove compartment. Press the glove compartment release tabs inward while raising the glove compartment. 21. Remove the instrument panel defroster opening grille. 22. Remove the instrument panel cowl top bolts. Vehicles with automatic transmission 23. If equipped, remove the high series floor console. For additional information, refer to Floor Console High Series in this section. 24. If equipped, remove the two screws and the restraint control module (RCM) cover.
7 Page 7 of 18 Vehicles with manual transmission 25. Remove the gearshift lever handle. 26. Remove the screws and the manual transmission consolette. All vehicles 27. Disconnect the RCM connector and remove the ground bolt. 28. Remove the instrument panel brace bolt from under the steering column opening.
8 Page 8 of Remove the two windshield side garnish mouldings. 30. Remove the passenger side instrument panel cowl side bolt. 31. Remove the instrument panel fuse panel door. 32. Remove the driver side instrument panel cowl side bolts.
9 Page 9 of Position the instrument panel away from the dash panel. 34. Disconnect the instrument panel harness from the body harness. 1. Loosen the bolt. 2. Disconnect the harness. 35. NOTE: This step requires an assistant. Remove the instrument panel. If necessary, transfer components to the new instrument panel. Installation All vehicles CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.
10 Page 10 of NOTE: This step requires an assistant. Position the instrument panel. 2. Connect the instrument panel harness to the body harness. 1. Connect the harness. 2. Tighten the bolt. 3. Align and install the instrument panel. 4. Install the driver side instrument panel cowl side bolts. 5. Install the instrument panel fuse panel door.
11 Page 11 of Install the passenger side instrument panel cowl side bolt. 7. Install the two windshield side garnish mouldings. 8. Install the instrument panel brace bolt from under the steering column opening. 9. Connect the RCM connector and install the ground bolt.
12 Page 12 of 18 Vehicles with manual transmission 10. Position the manual transmission consolette and install the screws. 11. Install the gearshift lever handle. Vehicles with automatic transmission 12. If equipped, position the RCM cover and install the two screws. 13. If equipped, install the high series floor console. For additional information, refer to Floor Console High Series in this section. All vehicles 14. Install the instrument panel cowl top bolts.
13 Page 13 of Install the instrument panel defroster opening grille. 16. Lower the glove compartment. Press the glove compartment release tabs inward while pulling downward on the glove compartment. 17. Connect the antenna cable in-line connector.
14 Page 14 of Connect the climate control vacuum harness connector. 19. Connect the blend door actuator electrical connector. 20. Install the passenger side air bag module. For additional information, refer to Section B. 21. Position the bulkhead electrical connector handle. 22. Install the bulkhead connector insulator.
15 Page 15 of Install the bulkhead wiring harness connectors. 1. Connect the electrical connectors. 2. Tighten the bolts. 24. Install the BJB. 25. Connect the electrical connectors and the ground wires at the passenger side cowl panel.
16 Page 16 of Install the two A-pillar lower trim panels. 27. Connect the BPP switch electrical connector. 28. If equipped, connect the CPP switch electrical connector. 29. Connect the upper intermediate steering shaft to the steering column shaft. 1. Install the intermediate shaft yoke to the steering column. 2. Install a new intermediate shaft pinch bolt. 30. If equipped, install the shift cable to the steering column. 1. Connect the shift cable to the steering column bracket. 2. Connect the shift cable to the steering column shift tube lever.
17 Page 17 of Install the instrument panel steering column opening cover reinforcement. 1. Position the instrument panel steering column opening cover reinforcement. 2. Install the bolts. 32. Install the instrument panel steering column cover. 1. Position the instrument panel steering column cover. 2. Install the screws. 33. Position the hood release handle and install the screws.
18 Page 18 of Position the parking brake release handle and install the screws. 35. Install the driver air bag module. For additional information, refer to Section B.
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