Passive Restraint System - Intermittently Sticks
91ford16
Article No.
91-8-1
04/17/91
RESTRAINT SYSTEM - PASSIVE - INTERMITTENT FRONT SEAT SHOULDER STRAP MOVEMENT OR STRAP IS STUCK AT "B" PILLAR
FORD: 1988-91 TEMPO
LINCOLN-MERCURY: 1988-91 TOPAZ
This TSB article is being republished in its entirety to revise the drill size used in Diagnosis.
ISSUE: The front seat shoulder strap retainer may operate intermittently or the strap may not move from the "B" pillar to the "A" pillar. This condition may be the result of a stuck "A" pillar limit switch plunger. This is caused by interference between the plunger and the upper portion of the track assembly.
ACTION: If service is required, use the following service procedure to identify the source of the concern and, if necessary, to install a front seat shoulder strap track front bracket assembly.
Figure 3:
Figure 4:
Figure 5:
Figure 6:
Figure 7:
DIAGNOSIS
1. With the shoulder strap at the "B" pillar location, use a Rotunda Passive Restraint System Tester No 007-0034A to check the system for an inoperative or stuck "A" pillar limit switch.
^ If the switch check is OK, the tester lamp for the "B" pillar limit switch should not glow, but the tester lamp for the "A" pillar limit switch should glow. Continue with system diagnosis.
^ If a Rotunda Passive Restraint Tester is not available, perform the following voltage measurements at the passive restraint module connector using a volt/ohmmeter. Refer to Figures 3 through 7 for meter connection details and related electrical circuit schematics.
For correct operation of the "A" pillar limit switch, the voltages should read those values shown in the following Voltage Measurement Chart.
VOLTAGE MEASUREMENT CHART
SHOULDER
STRAP
SIDE OF CARRIER VOLTAGE
VEHICLE CONNECTIONS LOCATION READING
Driver's Positive lead on pin 20 (BK/0), At "A" Pillar 0 Volts
Negative lead on pin 5 (BR/Y)
Not at "A" 8 to 12 V.
Pillar
Passenger's Positive lead on pin 20 (BK/0), At "A" Pillar 0 Volts
Negative lead on Pin 23 (GY)
Not at "A" 8 to 12 V.
Pillar
NOTE: IF THE ABOVE VOLTAGES ARE NOT PRESENT, THE "A" PILLAR LIMIT SWITCH MAY BE DEFECTIVE.
Figure 1:
2. Check to see if the "A" pillar limit switch plunger is hung up inside the front portion of the shoulder strap track assembly. If it appears that the plunger is stuck, insert a flat-bladed screwdriver upward between the lips of the inner and outer weatherseals and carefully free the plunger, Figure 1.
Figure 2:
3. Remove the shoulder strap track assembly. Refer to the Front Seat Shoulder Strap Track Assembly REMOVAL Procedure in this article.
4. Using two flat-bladed screw drivers, carefully pry the "A" pillar limit switch from the track assembly, Figure 2
Figure 8:
5. Connect a volt/ohmmeter to the connector terminals. Push the plunger in slightly and very gently wiggle it side-to-side in a clockwise motion, Figure 8.
NOTE: THERE SHOULD BE NO BREAK IN ELECTRICAL CONTINUITY DURING THIS PROCEDURE.
Figure 9:
6. Remove the two (2) screws retaining the "A" pillar limit switch bracket to the track assembly and remove the bracket, Figure 9.
7. Using a # 16 (.177) size drill as a gage, check the size of the bracket to track attaching holes in the "A" pillar limit switch bracket.
8. Observe the drill fit and take the following action:
^ If the drill does not fit easily into the holes, DO NOT REPLACE the limit switch bracket.
^ If the drill fits easily into the holes, REPLACE the limit switch bracket with new bracket having smaller holes (4.5 mm). Refer to the Parts Block for correct parts usage.
Figure 10:
Figure 11:
9. Before installing a new "A" pillar limit switch bracket to the body, inspect the "A" pillar limit switch bracket for possible rework.
^ If the bracket has a long narrow locator tab as shown in Figure 10, remove the tab. The reworked bracket should now look like the one shown in Figure 11.
^ If the bracket does not have a long narrow locator tab, proceed to Step # 10.
10. Before installing the "A" pillar limit switch bracket to the track assembly, apply Threadlock and Sealer (E0AZ-19554-AA), or equivalent, to all threads of the attaching screws.
CAUTION: USE CARE WHEN INSTALLING SCREWS TO AVOID STRIPPING THE TRACK ASSEMBLY.
Figure 9:
11. Install the reworked bracket to the track assembly, Figure 9. Make sure that attaching screws are tightened to 18-27 lb.in. (2-3 N-m).
12. Before installing the "A" pillar limit switch into the bracket, apply lithium/teflon grease (E7FZ-19590-A) to the limit switch plunger.
Figure 2:
13. Install the "A" pillar limit switch to the bracket/track assembly. Make sure the rubber limit switch bumper is installed correctly and the switch plunger passes through the plunger opening in the bracket as shown in Figure 2.
Figure 12:
Figure 13:
14. Position the track assembly to the "A" pillar sheet metal and check for interference between the weld flash build-up and the track at the "A" pillar to roof rail joint, Figures 12 & 13.
15. If no weld flash exists or weld flash does not contact the track in this area, install the track assembly. Make sure that all attaching fasteners are tightened to specifications. Refer to the shoulder strap track assembly installation procedure outlined later in this article.
Figure 13:
Figure 14:
16. If weld flash exists and contacts the track in this area, use a die grinder and remove only the weld flash, Figures 13 & 14.
CAUTION: DO NOT GRIND INTO WELD.
17. Metal finish and paint the area as required.
18. Check the system for proper operation.
FRONT SEAT SHOULDER STRAP TRACK ASSEMBLY - REMOVAL PROCEDURE
1. Remove the rear seat cushion and seat back assemblies. Refer to the 1990 Tempo/Topaz Shop Manual, Section 41-14, for service details.
2. Remove the interior trim as required to expose the passive restraint motor and track assembly. Remove the "A" pillar interior garnish moulding. Refer to the appropriate model year Tempo/Topaz Shop Manual, Sections 45-26, 45-03 and 45-16 respectively.
Figure 15:
3. Run the front seat shoulder strap full forward, Figure 15.
Figure 16:
4. Carefully disconnect the "B" pillar limit switch from the shoulder strap track assembly, Figure 16.
Figure 17:
5. Remove the shoulder strap anchor plug button and the attaching Torx bolt, Figure 17. Save parts for installation later.
Figure 17:
Figure 18:
Figure 20:
6. Remove the quarter panel sound deadener to gain access to the passive restraint motor/drive assembly, Figures 17, 18 and 20.
7. Remove the screws holding the vertical guide to body.
Figure 21:
8. Remove the screws holding the drive belt track and drive belt to the motor/drive assembly, Figure 21.
9. Disengage the drive belt from the drive gear teeth and remove the drive track, Figures 20 and 21.
Figure 18:
Figure 20:
10. Disengage the vertical guide from the drive track, Figures 18 and 20.
Figure 16:
11. Using the release tab, detach the vertical guide at the shoulder strap track rear mounting bracket ("B" pillar). See Figure 16.
Figure 16:
Figure 22:
12. Remove the two (2) screws holding the "B" bracket to the pillar, Figures 16 & 22.
Figure 18:
13. Remove the screw holding the "A" pillar limit switch and bracket assembly to the pillar, Figure 18.
14. Remove the two (2) screws retaining the overhead track to the body, Figure 18.
15. Rotate the track inboard to remove the track "A" pillar limit switch bracket retaining tab from its locating slot in the "A" pillar, Figure 18.
Figure 2:
16. Using two flat-headed screwdrivers, gently pry out and remove the "A" pillar limit switch, Figure 2.
FRONT SEAT SHOULDER STRAP TRACK ASSEMBLY - INSTALLATION PROCEDURE
1. Install the existing "B" pillar limit switch to the track assembly. Be sure that the rubber limit switch bumper is installed correctly.
Figure 16:
2. Secure the switch wiring to the bracket assembly with a new adjustable bundling strap. Be sure that the lock of the strap is positioned as shown in Figure 16.
Figure 18:
3. Loosely install the track assembly to the body, Figure 18.
Figure 18:
Figure 22:
4. Tighten the two (2) "B" pillar rear support bracket attaching bolts to 17-24 lb.ft. (23-33 N-m). See Figures 18 and 22.
Figure 18:
5. Tighten the overhead track retaining screws, Figure 18.
6. Install the limit switch bracket to the "A" pillar as follows:
a. Rest the limit switch bracket against the "A" pillar.
Figure 23:
b. Locate a new attaching hole location about midway between the old locator slot in the "A" pillar sheet metal and the top of the slot in the bracket as shown in Figure 23.
c. Prick-punch the location.
d. Use a suitable drill stop and drill a 5/16 " (4 mm) diameter hole into the sheet metal to prevent damage to the wiring located inside the "A" pillar.
Figure 23:
Figure 24:
e. Install the retaining screws as shown in Figures 23 & 24.
Figure 16:
Figure 18:
7. Insert the drive belt through the vertical guide and connect the guide to the "B" pillar rear support bracket assembly, Figures 16 & 18.
Figure 18:
Figure 19:
Figure 20:
8. Install the vertical guide to the body, Figures 18, 19 and 20.
Figure 20:
Figure 21:
9. Insert the drive belt into the motor/drive track, Figures 20 & 21.
Figure 18:
Figure 20:
10. Connect the drive track to the vertical guide, Figures 18 & 20.
11. Engage the drive belt motor/drive teeth and install the drive belt track retaining screws.
a. Tighten the screws to 22-35 lb.in. (2.5-4.0 N-m).
Figure 21:
b. Engage the rear lower guide to motor/drive track, Figure 21.
12. Install the front seat shoulder strap track to the track assembly as follows:
a. Return shoulder strap track carrier to "B" pillar position.
b. Grasp the strap anchor and pull the strap webbing out of the retractor in the console. Allow webbing to lie flat on the seat with no twist.
Figure 15:
Figure 17:
c. Install the shoulder strap to the track assembly by locating the anti-rotation pin in the strap carrier. Align it with the notch in the strap anchor, Figures 15 & 17.
Figure 17:
d. Install the Torx head attaching bolt. Tighten it to 8-12 lb.ft. (11-16 N-m) as shown in Figure 17.
e. Install the rubber plug button into the belt anchor cover as shown in Figure 17.
Figure 15:
NOTE: WHEN THE SHOULDER STRAP IS RETURNED TO THE "A" PILLAR POSITION, THERE SHOULD BE A HALF-TWIST IN THE STRAP WEBBING AS SHOWN IN FIGURE 15.
13. Operate the passive restraint system to be sure it is working OK.
14. Install interior trim.
15. Install the rear seat assembly. Be sure to tighten the attachments to proper specifications.
PART NUMBER PART NAME CLASS
F03Z-54602B38-A Bracket Assy. - Front Seat C
Shoulder Strap Track Front RH
- 1 Req.
F03Z-54602B39-A Bracket Assy. - Front Seat C
Shoulder Strap Track Front LH
- 1 Req.
E0AZ-19554-AA Threadlock and Sealer B
E7FZ-19590-A Lithium/Teflon Grease B
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 91-6-1
WARRANTY STATUS: Eligible Under Safety
Restraint Coverage, Basic
Warranty Coverage
OPERATION DESCRIPTION TIME
910801AT Both Sides 2.2 Hr.
910801A One Side 1.2 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
70602B38 42
OASIS CODES: 104000