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Attachment III - Fusion and Milan - Passenger Seat Recliner Replacement





(NEW!) Overview

Fusion and Milan Passenger Seat Recliner Replacement Attachment III

Fusion and Milan - Driver Seat Backrest Frame Replacement Attachment IV

Explorer Mountaineer and Sport Trac -
Driver and Passenger Seat Backrest Frame Replacement Attachment V

SERVICE PROCEDURE - ATTACHMENT III

FUSION AND MILAN - PASSENGER SEAT RECLINER REPLACEMENT

WARNING:
Never probe the electrical connectors on air bag, Safety Canopy(R) 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

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

Removal

1. Fold the seat backrest down to the fold flat position.

2. Remove and discard the safety belt retractor anchor bolt cover from the side shield.

3. NOTE: If equipped with a power seat position the seat track downward to remove the safety belt retractor anchor bolt.

Remove the safety belt retractor anchor bolt from the seat cushion frame.

4. NOTE: If equipped with a power seat fully raise the seat to aid in bolt removal. Position the seat to gain access to all four seat track-to-floor bolts.

5, Depower the Supplemental Restraint System (SRS). For additional information, refer to the WSM, Section 501-20B, SRS Depowering Procedure.

6. Remove the four seat track-to-floor bolt covers and the bolts.

7, Lift the seat to disengage the two forward seat locators from the floor and tip the seat rearward to access the seat harness electrical connectors.

8. WARNING:
Use care when handling the front passenger seat and track assembly Dropping the assembly, placing excessive weight on or sitting on a front passenger seat that is not secured in the vehicle may result in damaged seat components 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

NOTICE:
Use care when disconnecting the seat harness electrical connector. Excessive force on the assurance lever can break the connector mounting

Disconnect the seat harness electrical connectors and remove the seat

1. Slide and disengage the side air bag module electrical connector locking clip, release the tab, and disconnect the side air bag module electrical connector

2. Release the locking tab and rotate the assurance lever fully to disengage the seat harness electrical connector

3. Disconnect the electrical connector.

Disassembly

9. Position the seat backrest to the full upright position.





10. Position the seat cushion away from the side shield. Remove and discard the manual recliner handle spring clip (See Figure 1). Remove and discard the manual recliner handle by pulling outward on the handle.





11. If equipped with a power seat, using a suitable trim tool, remove the seat control switch knob See Figure 2.





12. Remove and discard the side shield from the seat cushion frame See Figure 3.

1. Pull outward on the middle and the rear of the side shield Carefully release the side airbag module wire harness locator from the side shield.

2. Using a suitable tool, remove and discard any remaining side shield retainers from the seat cushion frame.

3. If equipped with a power seat, disconnect the seat control switch electrical connector Remove the seat control switch from the side shield.





13. Using a small flat-blade screwdriver, remove the RH outboard recliner plastic rivet cover Remove and discard the RH and LH recliner plastic rivets See Figure 4.

NOTE:
The RH outboard side shown, LH side similar

14. NOTE: For proper routing during assembly, note the routing of the side air bag module wire harness and the pin-type retainers (RH side) If equipped, also note the routing of the heated seat wire harness and the pin-type retainers (LH side)

Remove the RH and LH outboard recliner covers. See Figure 5.

1. Release the clips at the front and rear of the outboard recliner covers by pulling outward.

2. Release the wire harness locators from the outboard recliner covers.

NOTE:
The RH outboard side shown, LH side similar.

(NEW!) 15. NOTE: For proper routing during assembly, note the orientation of the half moon cable end fitting.





Release the RH recliner cable housing from the recliner and unhook the cable end. See Figure 6.

(NEW!) 16 If equipped with a power seat, release the RH recliner cable pin-type retainer by compressing both tabs and discard. See Figure 7.





17. Pull the seat cushion trim cover in toward the center of the seat and twist rearward to release the trim cover retaining pocket from the metal tab of the LH recliner Separate the hook and loop from the safety belt buckle. See Figure 8.





18. Using suitable pliers unhook the LH recliner cable end and release the tabs to disconnect the cable from the cable bracket. See Figure 9.





19. If equipped with a heated seat, release the heated seat wire harness pin type retainer from the LH recliner. See Figure 10.







(NEW!) 20.





Remove the RH and LH recliners from the seat cushion and seat backrest frame. See Figure 11.

1. MANUALLY remove and discard the four recliner-to-seat cushion frame bolts (two each side) according to the following steps:

a. Using only hand wrenches, manually TIGHTEN each bolt approximately 1/8 of a turn to release the thread locking adhesive.

b. Manually LOOSEN and discard the bolts.

2. Position the backrest trim cover aside, MANUALLY remove and discard the four recliner-to-seat backrest frame Torx(R) bolts (two each side) according to the following steps:

a. Using only hand wrenches, manually TIGHTEN each bolt approximately 1/8 of a turn to release the thread locking adhesive.

b. Manually LOOSEN and discard the bolts.

NOTE:
Inboard recliner shown, outboard recliner similar.





21. Remove the RH and LH inboard recliner covers from the recliners. Discard the recliners. See Figure 12.

1. Using a small flat blade screwdriver, remove and discard the plastic rivets.

2. Release the inboard recliner cover.

3. Discard the recliners.

NOTE:
The LH inboard recliner cover shown, RH similar.

Assembly

22. Clip the inboard recliner covers to the new recliners and install the two new plastic rivets. See Figure 12.

(NEW!) 23. Install the new RH and LH recliners. See Figure 11.

1. Hand start and install the new RH and LH recliner-to-seat backrest frame Torx(R) bolts (two each side).

^ Tighten to 55 Nm (41 lb-ft).

2. Hand start and install the new RH and LH recliner-to-seat cushion frame bolts (two each side).

^ Tighten to 55 Nm (41 lb-ft).

24. NOTICE: The recliner cable synchronization cannot be completed until both the RH and LH recliner cables are completely installed onto the recliners Failure to follow these steps will compromise the recliner function.

NOTE:
Do not remove the recliner cable compensator black clip from the recliner compensator.





To synchronize the recliners unlock the black recliner cable compensator clip by sliding it away from the compensator housing. See Figure 13.

25. If equipped with a heated seat attach the heated seat wire harness pin-type retainer to the new LH recliner. See Figure 10.

26. NOTE: Make sure the LH recliner cable tabs are completely seated in the cable bracket Connect the LH recliner cable to the cable bracket and hook the cable end into the actuator. See Figure 9.

27. Using a suitable pair of pliers hook the RH recliner cable end into the actuator and clip the RH recliner cable housing onto the new recliner. See Figure 6.

(NEW!) 28. install a new RH recliner cable pin type retainer onto the recliner.

(NEW!) 29. The seat backrest should be in the upright position for the recliner synchronization.





30. Complete the recliner cable synchronization by shaking the recliner cable compensator a minimum of four times. Lock the compensator by pushing the black clip inward. See Figure 14.

31. Attach the hook-and-loop around the safety belt buckle. Pull the seat cushion trim cover in toward the center of the seat and attach the trim cover retaining pocket onto the metal tab of the LH recliner.

32. Install the RH and LH outboard recliner covers.

1. Route and attach the side air bag module wire harness and pin-type retainers (RH side). If equipped route and attach the heated seat wire harness and the pin-type retainers (LH side).

2. Attach the clips at the front and rear of the outboard recliner covers by pushing inward.

3. Install the new plastic rivets.

4. Install the RH outboard plastic rivet cover.

33. Install the new side shield onto the seat cushion frame.

1. If equipped with a power seat, install the seat control switch and connect the electrical connector.

2. Attach the side airbag wire harness locator onto the new side shield.

3. Align the retainers with the seat cushion frame, push in on the middle and the rear of the new side shield and snap into place.

4. If equipped with a power seat, install the seat control switch knob.

34. Install the new manual recliner handle by applying pressure until fully seated onto the new recliner.

Installation

35. If equipped with a manual seat, synchronize the seat tracks by aligning both track rails with the rear edge of the seat track base.

36. Position the seat into the vehicle.

37. Connect the seat electrical connectors.

1. Make sure the assurance lever of the electrical connector is in the fully released position.

2. Connect body harness electrical connector to the seat electrical connector.

3. Rotate the assurance lever while pushing the electrical connectors together until the lever handle is in the locked position.

4. Connect the side air bag module electrical connector. Install the electrical connector locking clip.

38. NOTE: Make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants.

Secure the seat.

1. Align the two forward seat mounting locators to the guide holes in the floor.





2. Install by hand all four seat track-to-floor bolts, then tighten. See Figure 15.

^ Tighten to 47 Nm (35 lb-ft) in the following sequence.

3. Install the four seat track-to-floor bolt covers.

39. NOTE: If equipped with a power seat, position the seat downward for the safety belt retractor anchor and bolt installation.

Position the safety belt retractor anchor onto the seat and install the anchor bolt and new cover. Tighten to 40 Nm (30 lb-ft).

40. NOTE: DO NOT prove out the SRS for the passenger seat until the Occupant Classification Sensor (OCS) System Zero Seat Weight Test has been completed.

Repower the Supplemental Restraint System (SRS). For additional information, refer to the WSM, Section 501-20B, SRS Repowering Procedure.

41. Perform the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. For additional information, refer to the WSM, Section 501-20B.
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