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Home >> Ford >> 2009 >> Mustang V6-4.0L >> Repair and Diagnosis >> Body and Frame >> Seats >> Seat Cushion >> Service and Repair >> Overhaul

Overhaul




Seat Cushion - Front





Driver Power Front Seat Cushion










Driver Manual Front Seat Cushion










Passenger Manual Front Seat Cushion










Passenger Power Front Seat Cushion









Disassembly

WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash.

WARNING: Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death.

NOTICE: To prevent system failure, it is necessary to carry out the Occupant Classification Sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset.

NOTE: Occupant Classification Sensor (OCS) system components [seat cushion foam pad, bladder with pressure sensor and Occupant Classification System Module (OCSM) module] are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor, OCSM and seat wire harness) must be installed as an assembly.

NOTE: To identify between a production OCS system and an OCS system service kit, inspect the OCSM electrical connector. A production OCS system allows the disconnection of the OCSM electrical connector.
An OCS system service kit has the electrical connector glued to the OCSM, it cannot and should not be disconnected or altered.

NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition switch is ON.

NOTE: When installing an OCS system service kit, refer to Air Bag Systems for the OCS service kit installation procedure.

NOTE: If a driver or passenger seat cushion heater mat is faulty, a new seat cushion foam pad must be installed with the heater mat. Do not reuse the original seat cushion foam pad. When installing an OCS service kit equipped with heated seats, a new cushion heater mat must be installed. Do not reuse the OEM OCS driver cushion heater mat. The OCS service kit does not come with a new cushion heater mat.

NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer.

All seats

1. Remove the front seat. For additional information, refer to Seat - Front Seat - Front.

2. Remove the front seat backrest. For additional information, refer to Seat Backrest - Front Seat Backrest - Front.

3. Remove the seat track. For additional information, refer to Seat Track - Manual Seat Track - Manual or Seat Track - Power Seat Track - Power.

4. If equipped, disconnect the seat control switch and lumbar control switch and remove the cushion side shield.

5. If equipped, release the retainers and remove the seat control switch and the lumbar control switch from the cushion side shield.

6. If equipped, disconnect the heated seat electrical connectors.

7. Release the cushion trim cover rear J-strip.

Driver seat and passenger seat with OEM Occupant Classification Sensor (OCS) system

8. Remove the cushion foam pad and cushion trim cover from the cushion frame.

Passenger seat

9. NOTICE: To prevent system failure, do not oversize the seat cushion frame holes used to rivet the Occupant Classification System Module (OCSM) in place.

Using a 5 mm (0.19 in) drill, remove the 2 rivets and separate the OCSM from the cushion frame.





10. NOTE: OEM OCS pressure sensor shown, OCS system service kit pressure sensor similar.

Bend to release the tab and remove the pressure sensor from the bracket.





11. NOTE: Note all wire harness routing for correct installation.

Release any seat wire harness routing pin-type retainers from the cushion frame.

12. If equipped with OEM OCS, remove the OCS bladder pin-type retainers.

13. NOTE: Note the cushion frame opening that the OCS components and seat wire harness are being routed through for installation.

Remove the OCS system components and wire harness from the cushion frame.





All seats

14. NOTE: Note all wire harness routing for correct installation.

If driver seat, release any pin-type retainer(s) and remove the seat wire harness from the cushion frame.

15. NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strip. The hook-and-loop strip can be torn from the seat cushion foam.

Separate the hook-and-loop strips, remove the hog rings and separate the cushion trim cover from the cushion foam pad.

Assembly

All seats

1. Position the cushion trim cover to the cushion foam pad, attach the hook-and-loop strips and install the hog rings.

2. If driver seat, route the seat wire harness to the cushion frame and attach the pin-type retainer(s) as noted during removal.

Passenger seat

3. WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash.

NOTICE: Failure to route the Occupant Classification Sensor (OCS) system seat and components through the correct seat cushion support opening can cause component failure.

Position the OCS components and seat wire harness through the cushion frame opening as noted during removal.
- Feed the hose, pressure sensor, wire harness, electrical connectors and OCSM through the opening in the cushion frame.





4. If equipped with OEM OCS, install the OCS bladder pin-type retainers.

5. Position the OCSM onto the seat cushion pan bracket and install the new rivets.
- The OCSM must be correctly positioned and securely riveted in place. Failure to do so can set a DTC in the RCM.





6. Bend the retaining tab back on the pressure sensor bracket.





7. Install the pressure sensor onto the cushion frame bracket, making sure the retaining tab is completely engaged.
- When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab.





8. Attach all seat wire harness routing clips and pin-type retainers to the cushion frame as noted during removal.

All seats

9. If equipped, connect the heated seat electrical connector.

10. If equipped, install the seat control switch and the lumbar control switch into the cushion side shield.
- Install the seat control switch knob.

11. If equipped, position the cushion side shield to the cushion frame and connect the seat control switch and lumbar control switch.

12. Position the cushion foam pad and trim cover to the cushion frame.

13. Install the seat track. For additional information, refer to Seat Track - Manual Seat Track - Manual or Seat Track - Power Seat Track - Power.

14. Install the seat backrest. For additional information, refer to Seat Backrest - Front Seat Backrest - Front.

15. Install the seat. For additional information, refer to Seat - Front Seat - Front.

16. Repower the SRS. If the passenger seat has been serviced, do not prove out the SRS at this time. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures of Air Bag Systems.

Passenger seat

17. WARNING: Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash.

WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash.

NOTICE: To prevent system failure, the following precautions must be taken before carrying out the Occupant Classification Sensor (OCS) system reset:
- Make sure the voltage to the Occupant Classification System Module (OCSM) is above 8 volts and less than 18 volts.
- Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes.
- Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process.
- Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process.


Carry out the OCS system reset.

18. If the first system reset attempt was unsuccessful, carry out a thorough visual inspection of the following and repair any concerns found.
- OCS system connector and wiring for damage

- Pressure sensor hose for kinks and/or damage

- Seat-related wiring harness and body wiring harness terminals and connectors for damage

19. NOTE: The ignition switch must be cycled after the OCS system reset.

Carry out a second OCS system reset. If the second attempt is unsuccessful, install a new OCS system service kit. For additional information, refer to Occupant Classification Sensor in Air Bag Systems.

All seats

20. Prove out the SRS as follows:

Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is detected, the air bag warning indicator will:

- fail to light.

- remain lit continuously.

- flash.

The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired.

Clear all continuous DTCs from the RCM using a scan tool.

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