Attachment V - Driver and Passenger Seat Backrest Frame 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 V

EXPLORER, MOUNTAINEER AND SPORT TRAC - DRIVER AND PASSENGER SEAT BACKREST FRAME REPLACEMENT

WARNING:
Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death

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.

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.

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

Removal

NOTE:
Driver seat shown unless otherwise noted

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





2. NOTE: If the metal retaining clip remains on the seat cushion frame, transfer the clip to the cover Using a suitable trim tool, remove the safety belt anchor bolt cover by lifting outward and upward. See Figure 1.

3. Remove the safety belt anchor bolt and separate the anchor from the seat.

4. Remove the seat track-to-floor bolt front cover.

1. The seat track must be back far enough for the rear of the cover to slide up and the locator tab to separate from the seat track.

2. Pull up at the front to release the clips, then slide up and forward to remove.

5. NOTE: If equipped with power seats, move the seat to its highest vertical position.





Position the seat forward so the seat track bracket does not engage the safety belt buckle and pretensioner bracket attached to the cushion frame. See Figure 2.

6. WARNING: The occupant classification sensor (OCS) rails have a built-in strain gauge which may operate incorrectly if an OCS rail is dropped by itself, dropped after it is installed to the front passenger seat or dropped after it is installed to a front passenger seat track assembly Use care when handling an OCS rail before or after it is installed to the front passenger seat or seat track assembly. Failure to follow these instructions may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash.

Remove the seat from the vehicle.

1. Remove the two seat track-to-floor rear bolt covers.

2. Remove and discard the four seat track-to-floor bolts.

3. Tip the seat rearward.

4. Release the seat wire harness pushpin.

5. Disconnect the seat electrical connector.

Disassembly





7. Remove and discard the manual recliner handle spring clip Remove the handle by pulling outward. See Figure 3.

8. If equipped with manual lumbar, adjust the lumbar support to the fully relaxed position by turning the control knob clockwise.

9. NOTICE: Do not use a tool to remove the manual lumbar control knob or damage to the side shield may occur.





Using both hands, pull outward on the manual lumbar control knob as shown. See Figure 4.





10. If equipped with a power seat using a suitable trim tool remove the seat control switch knob. See Figure 5.





11. Using a Phillips screwdriver remove and discard the side shield scrivet from the seat cushion frame. See Figure 6.





12. Remove the side shield from the seat cushion frame. See Figure 7.

1. Release the side shield front clip by pulling the front of the side shield outward from the seat cushion frame.

2. Release the two bottom retainers by pulling outward on the side of the shield. Lift up to detach the upper hooks.

3. Using a suitable trim tool, remove and discard the side shield rear pin4ype retainer.

4. If equipped with a power seat disconnect the seat control switch electrical connector.





13. 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 recliner. See Figure 8.





14. Release the two seat cushion trim cover J-clips from the rear of the cushion. See Figure 9.

NOTE:
Non-heated seat shown heated seat similar.





15. Using a suitable cutting tool cut the tie strap to release the side air bag wire harness from the wire bundle. See Figure 10.

16. 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 (LH side).





Disconnect the side air bag module electrical connector and if equipped the heated seat electrical connector and route the wire harness(es) out of the seat cushion frame. See Figure 11.

1. Disconnect the side air bag module electrical connector and release the pin-type retainers.

2. If equipped with a heated seat disconnect the heated seat electrical connector and release the pin-type retainers.

3. Route the wire harness(es) out of the seat cushion frame.

NOTE:
Heated seat shown, non-heated seat similar.

17. NOTE: For proper routing during assembly, note the routing of the side air bag module wire harness and the pin-type retainers.





Using a suitable trim tool, release the two side air bag module wire harness pin-type retainers from the back of the seat cushion frame.
18. Remove the safety belt buckle and pretensioner from the seat cushion frame. See Figure 12.

1. Release the seat cushion trim cover inboard J-clip.

2. Remove the black safety belt buckle and pretensioner electrical connector cover and disconnect the yellow electrical connector.

3. Disconnect the white safety belt buckle switch electrical connector.

4. Remove the two safety belt buckle and pretensioner nuts.

19. NOTE: For proper routing during assembly. note the routing of the lumbar cable and retainers.





If equipped with manual lumbar remove the manual lumbar control from the seat cushion frame. See Figure 13.

1. Remove the two screws and separate the lumbar control from the seat cushion frame.

2. Separate the manual lumbar cable from the control.

3. Route the manual lumbar cable out from the seat cushion frame.





20. Remove and discard the four recliner-to-cushion frame bolts and remove the seat backrest assembly from the seat cushion frame. See Figure 14.

NOTE:
Inboard side shown, outboard side similar.

21. Push in on the two head restraint guide sleeve release buttons and remove the head restraint





22. Remove and discard both of the head restraint guide sleeves by positioning a 3/16 in (5 mm) flatblade screwdriver at a 45° angle to the middle of the head restraint guide sleeve Push inward and apply slight downward pressure to release the lock feature. See Figure 15.

NOTE:
The seat backrest trim cover and foam pad are removed for clarity.

NOTE:
Typical head restraint guide sleeve shown, others similar





23. NOTE: For proper installation during assembly, note the location of the pushpins on the recliners Using a suitable tool, remove and discard the two pushpins that attach the backrest trim cover to the inboard and outboard recliners. See Figure 16.

24. NOTICE: Care must be used when separating the seat back trim cover from the hook-and-loop strip or the hook-and-loop strip may be damaged.





Remove the first row of hog rings from the foam pad. See Figure 17.

1. Reposition the backrest trim cover lower J-clip and release the hook-and-loop strips.

2. Fold the backrest trim cover back.

3. Using a suitable cutting tool, remove and discard the first row of hog rings.

NOTE:
Heated seat shown, non-heated seat similar.





25. Remove the backrest trim cover from the backrest foam pad. See Figure 18.

1. Release the hook-and-loop strips and fold the backrest trim cover back to access the second row of hog rings.

2. Using a suitable cutting tool, remove and discard the second row of hog rings.

26. Separate and remove the foam pad from the backrest frame.





27. Remove the side air bag module from the backrest frame See Figure 19.

1. Remove the three side air bag wire harness pin-type retainers.

2. Remove the two side air bag module bolts.





28. Remove the lumbar assembly by squeezing the sides of the clips together Discard the backrest frame. See Figure 20.

NOTE:
Manual lumbar is shown, static lumbar is similar.

Assembly

29. Install the lumbar assembly onto the new backrest frame by squeezing the sides of the lumbar spring clips together.

30. WARNING: Inspect the seat side air bag module cavity in the seat backrest foam pad for any foreign material If any foreign material is found, remove it Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increases the risk of serious personal injury or death in a crash

NOTICE:
Make sure the side air bag module wiring harness is not pinched between the side air bag module and the backrest frame Damage to the wire harness may occur

Install the new side air bag module U-nuts onto the new backrest frame.

31. Install the side air bag module onto the new backrest frame.

1. Position the side air bag module bracket onto the new backrest frame so the module bracket hook wraps around the new backrest frame. Hand start all of the bolts and tighten.

^ Tighten to 10 Nm (89 lb.in).

2. Attach the three side air bag wire harness pin-type retainers to the new backrest frame.

32. Install the backrest foam pad onto the new backrest frame.

33. WARNING: Front seat backrest trim covers installed on seats equipped with seat side air bags cannot be repaired. A new trim cover must be installed Cleaning is permissible. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increase the risk of serious personal injury or death in a crash.

NOTE:
When installing the new second row hog rings, position the hog ring on the listing wire first.

NOTE:
Make sure the head restraint guide sleeve holes in the backrest foam pad and the trim cover are aligned with the new backrest frame. Install the backrest trim cover onto the backrest foam pad/new backrest frame.

Install the backrest trim cover onto the backrest foam pad/new backrest frame.

1. Position the backrest trim cover onto the backrest foam pad/new backrest frame.

2. Using suitable hog ring pliers, attach the new second row hog rings to the listing wire.

3. Roll the backrest trim cover down and attach the hook-and-loop strips.

34. NOTE: When installing the new first row hog rings, position the hog ring on the listing wire first. Install the new first row hog rings.

1. Using suitable hog ring pliers, install the new first row hog rings onto the listing wire.

2. Attach the hook-and-loop strips and the backrest trim cover lower J-clip.

35. Attach the backrest trim cover to the inboard and outboard recliners with two new push pins.

36. NOTICE: The RH and LH head restraint guide sleeves are not interchangeable Failure to correctly install the head restraint guide sleeves may result in component failure.





Install the new head restraint guide sleeve with the large button and wide key on the LH side of the seat with the button facing the driver door. See Figure 21.

NOTE:
LH large button head restraint guide sleeve shown, RH small button guide similar.

37. Install the new head restraint guide sleeve with the small button and thin key on the RH side of the seat with the button facing the driver door. See Figure 21.





38. To install the head restraint guide sleeves, slide the sleeves through the backrest trim cover and the foam pad Using back and forth motion while twisting, apply downward pressure until the sleeve is seated onto the backrest frame as far as it will go See Figure 22.





39. Using a nonmarring mallet, such as a plastic dead blow or equivalent, seat the new head restraint guide sleeves Strike the top of the head restraint guide sleeve with moderate force until the sleeve is snapped into place on the new backrest frame. See Figure 23.

40. Make sure that both of the new head restraint guide sleeves are properly installed/locked into position by pulling upward on the sleeves If the sleeve(s) can be pulled out by hand, repeat the installation procedure. If, after the second installation, the sleeve(s) can still be removed, it will be necessary to replace the head restraint guide sleeve(s).

41. Hand start the four new recliner-to-cushion frame bolts and install the seat backrest onto the seat cushion frame.

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

42. Install the manual lumbar control onto the seat cushion frame.

1. Connect the manual lumbar cable to the backrest frame.

2. Attach the manual lumbar control to the seat cushion frame with the two screws and connect the cable.

3. Attach the cushion trim cover inboard J-clip.

43. Install the safety belt buckle and pretensioner onto the seat cushion frame.

1. Install the safety belt buckle and pretensioner nuts Tighten to 36 Nm (27 lb-ft).

2. Connect the white safety belt buckle switch electrical connector

3. Connect the yellow safety belt buckle and pretensioner electrical connector.

4. Install the black safety belt buckle and pretensioner electrical connector cover.

44. Attach the two side air bag wire harness pin-type retainers to the seat cushion frame.

45. Connect the side air bag module wire harness electrical connector, and if equipped, the heated seat wire harness electrical connector. Route the wire harness(es).

1. Attach the side air bag wire harness to the wire harness bundle with a new tie strap.

2. Attach all necessary pin-type retainers.

46. Attach the trim cover to the seat cushion frame.

1. Attach the two seat cushion trim cover J-clips to the rear of the seat cushion frame.

2. Attach the two rear trim cover retaining pockets.

47. Install the side shield onto the seat cushion frame.

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

2. Align and attach the side shield rear pin-type retainer with the metal recliner tab.

3. Align the side shield upper hooks with the seat frame and gently push down into position.

4. Push inward on the middle of the side shield to snap the two bottom retainers into place.

5. Push inward on the front of the side shield to snap the front clip into place.

48. Install the new side shield scrivet.

49. If equipped with a power seat, install the seat control switch knob by applying pressure until it completely seats.

50. If equipped with manual lumbar, install the control knob by firmly pushing until an audible click is heard.

51. Install the new spring clip on the manual recliner handle and install the handle by applying pressure until it completely seats.

Installation

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

53. Position the seat into the vehicle.

54. Connect the seat electrical connectors.

1. Tip the seat rearward.

2. Connect the seat electrical connector.

3. Attach the seat wire harness pushpin.





55. Secure the seat. See Figure 24.

1. Install the new seat track-to-floor front inboard bolt to its angled bracket and hand tighten.

2. Make sure the seat is aligned with the three remaining bolt holes and hand start the remaining new bolts. Do not force the remaining bolts if the seat is not correctly aligned.

^ Tighten all floor bolts to 40 Nm (30 lb-ft) in the following sequence.

56. Install the three seat track-to-floor bolt covers.

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

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

58. Install the safety belt anchor bolt cover.

59. 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.

Passenger Seat Only

60. 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.