FORD FCS-14000-DL User Manual
FCSD
Technical Training
INTERACTIVE STUDY GUIDE
2005
EXPEDITION/NAVIGATOR
NEW MODEL TECHNICIAN
TRAINING
FCS-14000-DL
2005 EXPEDITION/NAVIGATOR NEW MODEL TECHNICIAN TRAINING
COURSE CODE: 30N29F002-SEP-04
IMPORTANT SAFETY NOTICE
Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as
well as the personal safety of the individual doing the work. This manual provides general directions for accomplishing service
and repair work with tested, effective techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the
individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each.
Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his
personal safety nor the vehicle integrity by his choice of methods, tools or parts.
As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a
specific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are given
to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those
areas where carelessness can cause personal injury. The following list contains some general WARNINGS that you should
follow when you work on a vehicle.
•
Always wear safety glasses for eye protection.
•
Use safety stands whenever a procedure requires you to
be under the vehicle.
•
Be sure that the ignition switch is always in the OFF
position, unless otherwise required by the procedure.
•
Set the parking brake when working on the vehicle. If you
have an automatic transmission, set it in PARK unless
instructed otherwise for a specific service operation. If you
have a manual transmission it should be in RE-VERSE
(engine OFF) or NEUTRAL (engine ON) unless instructed
otherwise for a specific service operation.
•
Operate the engine only in a well-ventilated area to avoid
the danger of carbon monoxide.
•
Keep yourself and your clothing away from moving parts should be taken to ensure that the electric cooling fan is
when the engine is running, especially the fan and belts. completely disconnected when working under the hood.
•
To prevent serious burns, avoid contact with hot metal
parts such as the radiator, exhaust manifold, tail pipe,
catalytic converter and muffler.
•
Do not smoke while working on the vehicle.
•
To avoid injury, always remove rings, watches, loose
hanging jewelry, and loose clothing before beginning to
work on a vehicle. Tie long hair securely behind your
head.
•
Keep hands and other objects clear of the radiator fan
blades. Electric cooling fans can start to operate at any
time by an increase in underhood temperatures, even
though the ignition is in the OFF position. Therefore, care
The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or
service department operations. These recommendations and suggestions do not supersede or override the provisions of the Warranty
and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern.
The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved
for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or
testing procedures without notice and without incurring obligation. Any reference to brand names in this manual is intended
merely as an example of the types of tools, lubricants, materials, etc. recommended for use. Equivalents, if available, may be
used. The right is reserved to make changes at any time without notice.
WARNING: MANY BRAKE LININGS CONTAIN ASBESTOS FIBERS. WHEN WORKING ON BRAKE COMPONENTS, AVOID
BREATHING THE DUST. BREATHING THE ASBESTOS DUST CAN CAUSE ASBESTOSIS AND CANCER.
Breathing asbestos dust is harmful to your health.
Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when
made airborne by cleaning with compressed air or by dry brushing.
Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers.
Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags. The bag must be labeled per OSHA
instructions and the trash hauler notified as to the contents of the bag.
If a vacuum bag suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians
should wear government approved toxic dust purifying respirators.
OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians
concerned with performing brake or clutch service should be present in the area.
Copyright 2004 Ford Motor CompanyProduced and Coordinated by
Technical Support Operations
Ford Customer Service Division
September, 2004
CUSTOMER EXPECTATIONS
Customer Expectations: Service
1.
Make it convenient to have my vehicle
serviced at your dealership. explanation of the service performed.
2.
The Service Advisor should
demonstrate a genuine concern for of time after my service visit to ensure
my service needs. that I’m completely satisfied.
3.
Fix it right the first time.
4.
Complete servicing my vehicle in a
timely and professional manner.
Expectation 3
‘‘Fix It Right The First Time, on Time.’’
Both service advisors and technicians are important players when it comes to Expectation
#3.
5.
Provide me with a clear and thorough
6.
Call me within a reasonable amount
7.
Be responsive to questions or
concerns I bring to your attention.
Why
Customers tell us ‘‘Fixing It Right The First Time, on Time’’ is one of the reasons they
would decide to return to a dealer to buy a vehicle and get their vehicles serviced.
Technician Training
It is our goal to help the technician acquire all of the skills and knowledge necessary to
‘‘Fix It Right The First Time, on Time.’’ We refer to this as ‘‘competency.’’
Technician’s Role
Acquire the skills and knowledge for competency in your specialty via:
STST New Model
– Self Study – Self Study
– FordStar Broadcasts – FordStar Broadcasts
– Ford Multimedia Training (FMT) – Instructor Led
– Instructor Led
The Benefits
The successful implementation of expectations means:
– Satisfied customers
– Repeat vehicle sales
– Repeat service sales
– Recognition that Ford and Lincoln/Mercury technicians are ‘‘the Best in the
Business’’
TABLE OF CONTENTS
INTRODUCTION ............................................................................................................... Intro-1
Technical Training ........................................................................................................Intro-1
Ground Rules for Successful Completion....................................................................Intro-1
Logging On................................................................................................................... Intro-2
Keypad Operation ......................................................................................................... Intro-3
In-Dealership Training Map.......................................................................................... Intro-4
Purpose .........................................................................................................................Intro-5
Agenda ..........................................................................................................................Intro-5
LESSON 1: OVERVIEW......................................................................................................... 1-1
Objectives .......................................................................................................................... 1-1
Mechanical and Chassis Features.................................................................................... 1-2
Exterior Features............................................................................................................... 1-6
Interior Features ................................................................................................................ 1-8
Lifting and Jacking ........................................................................................................... 1-10
Maintenance Check Points .............................................................................................. 1-11
LESSON 2: CHASSIS............................................................................................................ 2-1
Objectives .......................................................................................................................... 2-1
Wheels and Tires............................................................................................................... 2-2
Driveshaft ......................................................................................................................... 2-11
Front Drive Axle/Differential............................................................................................. 2-12
LESSON 3: POWERTRAIN ................................................................................................... 3-1
Objectives .......................................................................................................................... 3-1
Engine - 5.4L..................................................................................................................... 3-2
Electronic Engine Controls.............................................................................................. 3-36
Fuel Tank and Lines ........................................................................................................ 3-38
Engine Special Service Tools.......................................................................................... 3-39
Automatic Transmission .................................................................................................. 3-40
Transmission Cooling ...................................................................................................... 3-62
6HP26 Transmission Special Service Tools................................................................... 3-63
LESSON 4: ELECTRICAL..................................................................................................... 4-1
Objectives .......................................................................................................................... 4-1
Climate Controlled Seats ................................................................................................... 4-2
Warning Devices................................................................................................................ 4-3
Instrument Cluster Lighting................................................................................................ 4-4
Charging System............................................................................................................... 4-5
Vehicle Security Module.................................................................................................... 4-6
Module Communication Network....................................................................................... 4-7
APPENDIX................................................................................................................Appendix-1
Appendix: Essential Special Service Tools .......................................................... Appendix-1
Order Form........................................................................................................... Appendix-3
Glossary Of Terms ............................................................................................... Appendix-5
2005 Expedition/Navigator New Model Technician Training 02-SEP-04 i
TABLE OF CONTENTS
NOTES
2005 Expedition/Navigator New Model Technician Training02-SEP-04ii
INTRODUCTION
FCSD
Technical Training
The distance learning course you are about to take is intended to give you new knowledge and information about
diagnosing and servicing Ford and Lincoln/Mercury vehicles. We hope you will apply this knowledge and
information to ‘‘Fix It Right The First Time’’ as part of the effort to satisfy our customer, the owners of Ford and
Lincoln/Mercury products.
Ground Rules for Successful Completion
This course is what we call ‘‘score based.’’ Successful completion of this course requires a passing score of 80%
or greater on the Post-Test questions. Achievement of 80% or greater will result in a ‘‘PASS’’ in your STARS
training history. A score of less than 80% results in a ‘‘FAIL’’ in your STARS training history. If you logon and
participate in the class, but choose NOT to answer any of the questions, you will receive an ‘‘AUDIT’’ in your
training history. You may return to complete the test in a future class session, if desired. Completion of the test
will replace the ‘‘AUDIT’’ in your STARS training history.
2005 Expedition/Navigator New Model Technician Training 02-SEP-04 Intro-1
INTRODUCTION
LOGGING ON
Your response keypad transmits data and voice between you and the host site via telephone lines and satellite. It is
your ‘‘lifeline,’’ connecting you to the instructor as well as to other participants. Using the keypad, you can
become fully involved in the seminar, asking questions and contributing relevant comments.
To log on at the beginning of the broadcast session:
1. Enter your Social Security number (in response to the keypad prompt). If you press an incorrect key, press
CLEAR and re-enter the numbers.
2. Press ENTER.
3. The system validates your ID number by displaying your name on your keypad. If your name does not appear
on the keypad, re-enter your ID number.
4. If you cannot successfully log on, contact the FORDSTAR Help Desk:
USA Dealers call 1–800–790–HELP (4357).
Canadian Dealers call 1–800–467–8925.
2005 Expedition/Navigator New Model Technician Training02-SEP-04Intro-2
INTRODUCTION
KEYPAD OPERATION
CALL Key
•
Press the CALL key if you have a question or comment. This places you in the call queue. The system indicates
your name and location to the instructor.
•
It takes approximately 60 seconds for the instructor to respond. If you change your mind about asking the
question, simply press the CALL key again. As long as the instructor has not accepted your call, this takes you
out of the call queue.
WAIT and SPEAK Lights
•
The red WAIT light illuminates when your call is received and placed in the call queue.
•
When the instructor calls on you, the green SPEAK light illuminates and your microphone is activated.
•
The microphone is the gray dot between the SPEAK and WAIT lights. Speak in a normal tone of voice from a
normal sitting position. The instructor will hear you — as will all the other students, wherever they are located.
FLAG Key
•
Use the FLAG key when requested by the instructor. The FLAG key is usually used to alert the instructor that
you have completed tests or exercises.
2005 Expedition/Navigator New Model Technician Training 02-SEP-04 Intro-3
INTRODUCTION
IN-DEALERSHIP TRAINING MAP
2005 Expedition/Navigator New Model Technician Training02-SEP-04Intro-4
INTRODUCTION
PURPOSE
The purpose of this FORDSTAR course is to provide Ford and Lincoln/Mercury service technicians with the
knowledge needed to understand new systems, new or updated components and unique diagnostic and service
procedures for the 2005 Expedition/Navigator.
AGENDA
The information in this course is presented in the following lessons:
•
Lesson 1: Overview
•
Lesson 2: Chassis
•
Lesson 3: Powertrain
•
Lesson 4: Electrical
2005 Expedition/Navigator New Model Technician Training 02-SEP-04 Intro-5
INTRODUCTION
NOTES
2005 Expedition/Navigator New Model Technician Training02-SEP-04Intro-6
OBJECTIVES
•
Identify the new powertrain applications for Expedition and Navigator.
•
Identify exterior features.
•
Identify interior features.
•
Identify lifting and jacking points.
•
Identify maintenance check points.
LESSON 1: OVERVIEW
2005 Expedition/Navigator New Model Technician Training 02-SEP-04 1-1
LESSON 1: OVERVIEW
Mechanical and Chassis Features
Mechanical and Chassis Features
•
5.4L 3-Valve Triton Engine w/Variable Cam Timing.
•
6HP26 Automatic Transmission (Navigator only).
•
4R75E Automatic Transmission (Expedition only).
2005 Expedition/Navigator New Model Technician Training02-SEP-041-2
Engine - 5.4L
LESSON 1: OVERVIEW
5.4L 3-Valve Triton Phaser
The 2005 Expedition and Navigator are available with one engine:
•
New for 2005, the 5.4L 3-valve Triton V8.
– 300 horsepower @ 5,000 rpm
– 365 lb-ft of torque @ 3,750 rpm
– Variable cam timing
– Three valves per cylinder
–Electronic Throttle Control (ETC)
Rather than focusing on a single item to gain improvements in power, Ford used an approach that included
advancements on multiple fronts. These improvements contribute to overall power with reduced NVH, at low
engine speeds. Some of these changes are outlined below:
•
The three-valve design achieves same benefits as a four-valve design.
– Three-valve design balances the forces generated by the valve and spring movement.
– Reduces engine noise.
2005 Expedition/Navigator New Model Technician Training 02-SEP-04 1-3
LESSON 1: OVERVIEW
•
Variable Cam Timing (VCT) varies cam timing to match performance demands.
•
Charge Motion Control Valves (CMCV) manage the flow of air into the cylinders.
•
Vibration-resistant ribbing and reinforcement in the lower engine block help manage and tune sound and
vibration.
– The engine block ribbing strengthens the block wall similar to cross reinforcements in a building wall.
2005 Expedition/Navigator New Model Technician Training02-SEP-041-4
Automatic Transmission
LESSON 1: OVERVIEW
6HP26 Transmission
The 2005 Expedition will use the 4R75E automatic transmission like the 2004 and 2005 F-150, while the
Navigator uses the all-new 6HP26 automatic.
The 6HP26 6-speed transmission uses total electronic control for all functions. The Transmission Control Module
(TCM) and the main control valve body units are combined and installed as a single unit inside the automatic
transmission. Hydraulic functions are directed by electronic solenoids to control:
•
engagement feel
•
shift feel
•
shift scheduling
•
modulated Torque Converter Clutch (TCC) applications
•
engine braking
2005 Expedition/Navigator New Model Technician Training 02-SEP-04 1-5
LESSON 1: OVERVIEW
Exterior Features
2005 Navigator Exterior
•
New body side cladding
– Bold new body side cladding is added to the 2005 Lincoln Navigator. The cladding is painted body color and
enhances as well as protects the exterior appearance.
•
New front fascia
– An agressive front fascia is standard on the Lincoln Navigator and comes with integral fog lamps and front
spoiler. High Intensity Discharge (HID) headlamps are optional on all models.
2005 Expedition/Navigator New Model Technician Training02-SEP-041-6
LESSON 1: OVERVIEW
2005 Expedition Exterior
•
New badging for Limited and FX4 (mid 4th quarter availability).
– Expedition for 2005 comes with new badging when equipped with the Limited and FX4 packages.
•
New power fold side view mirrors.
– Expedition Limited for 2005 comes with new power fold side view mirrors. The mirrors are controlled by a
switch that is integral with the power mirror switch.
2005 Expedition/Navigator New Model Technician Training 02-SEP-04 1-7
LESSON 1: OVERVIEW
Interior Features
2005 Navigator Interior
•
New 6HP26 automatic transmission gear selector.
– Lincoln Navigators are equipped with a new 6HP26 transmission. The gear selector allows for manual or
automatic selection of first through fourth gear (O/D disabled) and first through sixth (O/D enabled). O/D is
enabled by moving the gear selector handle to the left while in the D6/D4 gate and is disabled by moving it
to the right.
– To accomodate the new gear selector for the 6HP26 transmission, the center console has been updated.
•
New front seats.
– The 2005 Lincoln Navigator features restyled front seats to improve seating comfort and support.
2005 Expedition/Navigator New Model Technician Training02-SEP-041-8
LESSON 1: OVERVIEW
2005 Expedition Interior
The 2005 Expedition receives minor trim and finish updates as:
•
Power fold side view miror switch (Limited only).
– The power fold mirrors are operated from a switch that is integral with the power mirror switch.
– In contrast to the power folding mirror switch already available in the Navigator, to retract or extend the
folding mirrors, rotate the mirror adjustment knob to the center position. Pressing the switch down one time
will fold the mirrors inward. Pressing the button again will return the mirrors to their normal position.
2005 Expedition/Navigator New Model Technician Training 02-SEP-04 1-9
LESSON 1: OVERVIEW
Lifting and Jacking
Lifting and Jacking Points
The front and rear lifting and jacking locations are as indicated.
2005 Expedition/Navigator New Model Technician Training02-SEP-041-10
Maintenance Check Points
LESSON 1: OVERVIEW
Maintenance Check Points (Navigator Shown)
Item Description Item Description
1 Cabin Air Filter 6 Engine Coolant
2 Engine Air Filter 7 Engine Oil Fill
3 Power Steering Fluid 8 Windshield Washer Solvent
4 Engine Oil Dipstick 9 Battery
5 Brake Fluid
All maintenance point locations are carry-over from 2004 with the exception of the transmission fluid (on Lincoln
Navigator) and air filter element (on both). Expedition has a conventional transmission dipstick located near the
right rear corner of the engine. Refer to the Workshop Manual for the proper maintenance schedule and fluid
specifications.
2005 Expedition/Navigator New Model Technician Training 02-SEP-04 1-11
LESSON 1: OVERVIEW
NOTES
2005 Expedition/Navigator New Model Technician Training02-SEP-041-12
OBJECTIVES
•
Identify changes to the TPMS.
•
Identify new suspension system features.
•
Identify new drive axle/differential driveline features.
LESSON 2: CHASSIS
2005 Expedition/Navigator New Model Technician Training 02-SEP-04 2-1
LESSON 2: CHASSIS
Wheels and Tires
Tire Pressure Monitor
•
TPMS functionality is integrated into Vehicle Security Module (VSM) located in the right kick panel.
•
Communicates with sensor at 315 MHz.
•
Blue colored sensor (315 MHz), unique for 2005 Expedition and Navigator.
•
Sensor Training process is same as previous TPM system (with exception of spare tire).
•
2004 sensor (Black, 433 MHz) will NOT work on 2005 Expedition or Navigator.
•
Sensor removal and installation process is same as 2004 system.
•
Cluster messages for TPMS are different than 2004.
•
A separate warning indicator is used on Expedition models that are not equipped with the optional message
center.
2005 Expedition/Navigator New Model Technician Training02-SEP-042-2
LESSON 2: CHASSIS
TPMS General Information
Temperature fluctuation changes tire inflation pressure 7KPa per 12 degrees Celsius (1 psi per 10 degrees F)
Article #: SSM 17496 Date: 01/16/2004: TPMS SYSTEM-DO NOT USE AFTERMARKET WHEELS. SOME
2003-2004 EXPEDITION/NAVIGATOR/AVIATOR/EXPLORER/MOUNTAINEER VEHICLES MAY
EXHIBIT A TIRE PRESSURE MONITORING SYSTEM (TPMS) WARNING, OR OTHER RELATED
CONDITIONS, IF AFTERMARKET WHEELS ARE INSTALLED. FORD MOTOR COMPANY DOES NOT
RECOMMEND USING AFTERMARKET WHEELS ON ANY VEHICLES, ESPECIALLY TPMS EQUIPPED
VEHICLES. ORIGINAL EQUIPMENT (OE) WHEELS ARE SPECIFICALLY DESIGNED TO
ACCOMMODATE TPMS SENSORS. AFTERMARKET WHEELS MAY NOT BE COMPATIBLE WITH
THESE SENSORS, AND USE OF NON-OE WHEELS MAY RESULT IN ILLUMINATION OF THE TPMS
WARNING INDICATOR, LOSS OF TIRE PRESSURE, TPMS SENSOR DAMAGE OR LOSS OF TPMS
FUNCTIONALITY. FORD DOES NOT SUPPORT DISABLING THE TPMS SYSTEM. IT IS THE
INSTALLER’S RESPONSIBILITY TO ENSURE AFTERMARKET WHEELS PROVIDE EQUIVALENT FIT
AND FUNCTION AS THE OE WHEELS BEING REPLACED INCLUDING TPMS FUNCTIONALITY.
NOTE: This SSM also applies to 2005 model year Expedition and Navigators vehicles.
2005 Expedition/Navigator New Model Technician Training 02-SEP-04 2-3
LESSON 2: CHASSIS
Functionality - 2005 Model Year
Sensor Wheel Package
Item Description Item Description
1 Blue, 315 Mhz Tire Pressure Sensor
•
4-sensor system (road tires only, does not include spare).
•
RF-based.
– Sensors transmit pressure and unique ID to VSM (integrated system).
– Receiver (TPM integral to VSM) receives information, processes information, and communicates status to
the cluster via MS-CAN link.
•
TPMS warnings displayed on message center (if equipped).
•
All units use NHTSA defined telltale.
2005 Expedition/Navigator New Model Technician Training02-SEP-042-4
Sensor Description
LESSON 2: CHASSIS
TPMS Sensor
Item Description Item Description
1 Transmitter Case 5 Aluminum Valve
2 Air Hole: Top 6 Inside: Core
3 Potted Surface: Bottom 7 Nut
4 Grommet 8 Cap
•
315 MHz (Blue), Manchester Encoded, AM.
•
Pressure Sampling / Transmission.
– Stationary – 15 minute sample /1 hour transmission.
– Rolling – 30 second sample/1 minute transmission.
•
Motion switch sampling rate – 10 second.
•
Full Scale Pressure Range: 0 – 64 psi.
•
24 Bit Electronic ID Code.
2005 Expedition/Navigator New Model Technician Training 02-SEP-04 2-5
LESSON 2: CHASSIS
Module Description
•
TPM System integrated into Vehicle Security Module (VSM).
•
Module designed to:
– Receive tire pressure and sensor information (315MHz transmissions from sensors).
– Process input information, determine correct status, and associate sensors with module (learn).
– Communicate status to message center via MS-CAN.
– Output to horn relay (self test and manual learn mode).
2005 Expedition/Navigator New Model Technician Training02-SEP-042-6
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