Fuel System - Throttle Cable Routing/Splash Shield Mods

Article No.
03-10-6

05/26/03

ENGINE - 4.0L SOHC - THROTTLE CABLE ROUTING
AND SPLASH SHIELD MODIFICATION WHEN
REPLACING THROTTLE CABLE DURING NORMAL
SERVICE

FORD:
2002 EXPLORER

MERCURY:
2002 MOUNTAINEER

ISSUE
2002 LHD 4dr Explorer/Mountaineer vehicles equipped with the 4.0L SOHC engine may require a revised throttle cable routing and splash shield modification if throttle cable replacement is necessary during service. This is due to throttle cable service replacement part design changes.








ACTION
Due to service part and routing changes (Figures 1 and 2), it will be necessary to eliminate some material on the splash shield between the already existing cable outlet holes if throttle cable replacement is required during normal service.

SERVICE PROCEDURE

NOTE
IT IS NOT NECESSARY TO REPLACE THE SPLASH SHIELD WHEN REPLACING THE THROTTLE CABLE WITH THE UPDATED PART NUMBER, ONLY A MODIFICATION WILL BE NECESSARY TO THE ORIGINAL SPLASH SHIELD.

1. Remove the screws and the accelerator control splash shield.

2. Disconnect the accelerator cable from the throttle body.

3. Squeeze the tabs and remove the accelerator cable from the bracket.

4. Disconnect the accelerator cable from the retainers.

5. Remove the accelerator cable from the rubber plunger.

6. Remove the rubber plunger from the throttle pedal.

7. Remove the accelerator cable from the throttle pedal.

8. Pull the accelerator cable boot to the unlock position.

9. Remove the accelerator cable boot and cable from the dash panel into the engine compartment and remove the accelerator cable.





10. Modify existing splash shield cable holes to allow redesigned cable installation (Figure 3).

11. To install, reverse the removal procedure.

OTHER APPLICABLE ARTICLES: NONE

WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage

OPERATION DESCRIPTION TIME

031006A Modify Splash Shield 0.4 Hr.
(Includes Time To Replace
Throttle Cable. Should
Only Be Done During
Normal Service)

DEALER CODING
CONDITION
BASIC PART NO. CODE
9A758 42

OASIS CODES: 404000, 490000





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