Attachment III - Technical Information
OVERVIEWThis program involves replacing the upper seat track support assembly on power seats. On Taurus and Sable models, either just the driver seat or both front seats will be power-equipped. Thunderbird models are only available with a driver power seat.
SERVICE PROCEDURE
TAURUS/SABLE
1. Move the seats so the front and rear vertical motors are in the middle of their travel.
2. Move the seat horizontally to access all seat-to4loor fasteners.
3. Refer to Section 501 - 10 of the 2004 Taurus/Sable Workshop Manual and perform the following:
A) Depower the supplemental restraint system.
B) Remove the seat assembly from the vehicle.
C) Remove the front seat backrest assembly.
D) Remove the seat track assembly.
4. Replace the seat track upper support assembly. Refer to the Seat Track Upper Support Assembly Replacement procedure in this Attachment III.
5. Refer to Section 501 - 10 of the 2004 Taurus/Sable Workshop Manual and perform the following:
A) Install the seat track assembly to the seat.
B) Install the front seat backrest assemblies.
C) Install the seats into the vehicle.
D) Repower the supplemental restraint system.
6. Cycle the driver seat through its full range of travel forward and backward to reset the seat position sensor.
THUNDERBIRD
1. Move the seat so the front and rear vertical motors are in the middle of their travel.
2. Move the seat horizontally to access all seat-to-floor fasteners.
3. Refer to Section 501-10 of the 2004 Thunderbird Workshop Manual for power seat track removal procedures. Follow the procedures as written with the following exceptions:
^ DO NOT perform the published deactivation/reactivation procedure. Instead, perform the Thunderbird Supplemental Restraint System Depower/Repower procedure provided in this Attachment III. The 2004 Thunderbird Workshop Manual will be updated at a later date. The service labor time standard for this program includes time for this depower/repower procedure NOT deactivation/reactivation.
^ When disassembling the front seat cushion following the published workshop manual exploded view, perform only the following steps:
Steps 5 and 6 - Backrest pivot bolt and cover
Step 7 - Power seat switch disconnect
Steps 9, 10 and 11 - Side shield removal
Steps 14, 15 and 16 - Safety belt buckle bolt and buckle
Steps 17 through 20 - Cushion recliner bolts and spacers
Steps 22 and 23 - Seat track bolts and track
Also, remove the connector bracket from the rear of the seat frame assembly.
NOTE:
All other steps listed on the exploded view are not required and should not be performed.
4. Replace the seat track upper support assembly. Refer to the Seat Track Upper Support Assembly Replacement procedure in this Attachment III.
5. Refer to Section 501 - 10 of the 2004 Thunderbird Workshop Manual seat reassembly and reinstallation procedures. While following the published exploded view, perform only the following steps:
Steps 22 and 23 - Seat track bolts and tracks
Steps 17 through 20 - Cushion recliner bolts and spacers
Steps 14, 15 and 16 - Safety belt buckle and bolt
Steps 9, 10 and 11 - Side shield
Step 7 - Power seat switch
Step 5 and 6 - Backrest pivot bolt and cover
Install the connector bracket to the rear of the seat frame assembly.
NOTE:
All other steps listed in the exploded view are not required.
6. Perform the supplemental restraint system repower procedure as outlined in this Attachment III.
7. Cycle the driver seat through its full range of travel forward and backward to reset the seat position sensor.
THUNDERBIRD SUPPLEMENTAL RESTRAINT SYSTEM DEPOWER/REPOWER
Depower Procedure
WARNING:
ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
WARNING:
NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
WARNING:
TO REDUCE THE RISK OF PERSONAL INJURY, DO NOT USE ANY MEMORY SAVER DEVICES.
NOTE:
All 2004 Thunderbird vehicles are equipped with a supplement restraint system (SRS). During service the SRS must be depowered.
NOTE:
The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate an SRS fault.
NOTE:
The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Turn all vehicle accessories OFF.
2. Turn the ignition switch to OFF.
3. Remove the RH kick panel cover and remove the RCM fuse F2.14 (10A) from the central junction box (CJB). For additional information refer to the Wiring Diagram Manual.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE (1) MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
Disconnect the battery ground cable and wait at least one (1) minute. For additional information, refer to Section 414-00 of the 2004 Thunderbird Workshop Manual.
Repower Procedure
1. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected.
2. Turn the ignition switch from OFF to ON.
3. Install the RCM fuse F2.14 (10A) to the CJB and install the RH kick panel cover.
4. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING BLOCKING OR SET IN FRONT OF ANY AIR BAG MODULE WHEN THE BATTERY GROUND CABLE IS CONNECTED.
Connect the battery ground cable.
5. 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 indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six (6) seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will either:
^ 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 indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five (5) sets of five (5) beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a diagnostic tool.
SEAT TRACK UPPER SUPPORT ASSEMBLY REPLACEMENT
DISASSEMBLY
1. Remove the connector bracket from the upper track support assembly (Taurus/Sable only).
2. To change the seat track horizontal position, apply power and ground to the pins shown. See Figure 1.
3. NOTE: If not correctly positioned, the seat track motor assembly cannot be removed from the seat track.
Position the seat track horizontally by applying power and ground to the seat track motor pins. Position the outboard track most of the way forward so that two teeth are showing next to the outboard retainer clip and a flat spot on the drive tube (not shown) is positioned upward. See Figure 2.
4. NOTE: This step is critical so that during installation the inboard and outboard tracks can be checked to make sure they are in alignment with each other.
Mark the position of the outboard track C-channel to the plastic-coated slide as shown. See Figure 3.
5. Mark the position of the inboard track C-channel to the plastic-coated slide as shown. See Figure 4.
6. Remove the two (2) nuts at the lift links. See Figure 5.
7. NOTE: The drive tube is press-fit to stub shafts on each end. A hammer may be necessary to separate the drive tube.
NOTE:
The drive tube must be clamped at the inboard track gear stub shaft to allow the drive tube to separate at the seat track motor gear stub shaft on the opposite side of the seat.
Clamp the locking pliers on the flats of the drive tube where it reaches over the inboard track gear stub shaft. Tap on the locking pliers, separate the drive tube from the seat track motor assembly stub shaft and remove the inboard track and drive tube. See Figure 6.
8. Remove the two (2) motor-to-track nuts (on Thunderbird, one nut was previously removed with the connector bracket). See Figure 7.
9. Remove the outboard retainer clip. See Figure 8.
10. Remove the two (2) bolts holding the seat track motor assembly to the outboard track. See Figure 9.
11. NOTE: The pinion cage will be removed with the outboard track.
Carefully pry between the seat track motor assembly and the outboard track and remove the outboard track. See Figure 10.
12. Carefully pry and remove the two (2) support straps. See Figure 11.
13. Pry and remove the seat track motor assembly from the upper support assembly. See Figure 12.
ASSEMBLY
1. NOTE: The front and rear height adjustment gears do not have to mesh with the seat track motor assembly gears at the same teeth as when disassembled.
NOTE:
Make sure the motor is positioned right side up.
Install the seat track motor assembly to the upper support assembly. See Figure 13.
A) Be sure to install the seat track motor assembly pivots through the front and rear height adjustment gear brackets.
B) Mesh the seat track motor assembly gears to the front and rear height adjustment gears. There should not be a gap between the upper support assembly gears and the seat track motor assembly housing.
2. WARNING: THE SUPPORT STRAPS ARE LOAD-BEARING COMPONENTS DURING A CRASH EVENT. THE SUPPORT STRAPS MUST BE CORRECTLY INSTALLED DURING ASSEMBLY OF THE SEAT TRACK. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN THE FAILURE OF THE SEAT TO PERFORM AS DESIGNED WITH RESULTANT RISK OF PERSONAL INJURY TO THE VEHICLE OCCUPANT.
NOTE:
The support straps must fit flush against the front and rear height adjustment gears. Install the support straps. See Figure 11.
3. Check to make sure the index marks on the outboard track C-channel and plastic-coated slide are still in alignment. If necessary, slide the track to realign the marks. See Figure 14.
4. WARNING: THE PINION CAGE IS A LOAD-BEARING COMPONENT DURING A CRASH EVENT. THE PINION CAGE MUST BE CORRECTLY INSTALLED DURING ASSEMBLY OF THE SEAT TRACK. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN THE FAILURE OF THE SEAT TO PERFORM AS DESIGNED WITH RESULTANT RISK OF PERSONAL INJURY TO THE VEHICLE OCCUPANT.
Position the pinion cage onto the outboard track. See Figure 15.
5. Install the outboard track as follows: See Figure 16.
A) Position the track studs through the seat track motor assembly.
B) While sliding the track studs through the seat track motor assembly, position the pinion cage opening around the seat track motor assembly gear.
C) Fit the support straps and seat track motor assembly gear bushing alignment pins into the track openings.
6. When assembled, make sure the outboard track, support straps, front and rear height adjustment gears and seat track motor assembly all fit flush against each other. Make sure the support straps and seat track motor assembly gear bushing alignment pins fit into the track openings. See Figure 17.
7. CAUTION: Do not overtighten or damage will occur.
Install the two (2) bolts holding the seat track motor assembly to the outboard track. Tighten to 12 Nm (9 lb-ft). See Figure 9.
8. Position the connector bracket (Thunderbird only) and install the two (2) nuts. Tighten to 14 Nm (10 lb-ft). See Figure 7.
9. Install the outboard retainer clip. See Figure 8.
10. CAUTION: The index marks on the outboard track C-channel and plastic-coated slide must align at this step.
Check to make sure the index marks on the outboard track C-channel and plastic-coated slide are still in alignment. If necessary, slide the track to realign the marks. See Figure 3.
11. Check to make sure the index marks on the inboard track C-channel and plastic-coated slide are still in alignment. If necessary, slide the track to realign the marks. See Figure 18.
12. NOTE: When assembled, a small gap between one of the gears and the drive tube may exist. Assemble the seat track motor assembly, upper support assembly and inboard track together as follows: See Figure 19.
A) Align the drive tube to the motor stub shaft. Tap the nose of the inboard track gear toward the seat track motor stub shaft.
B) To keep the motor assembly level, position a block of metal or wood behind the motor gear.
C) While tapping the parts together, simultaneously engage the front and rear lift links to the inboard track.
D) When the lift links are up against the inboard track, with the bushings through the hole and seated, the drive tube is fully engaged.
13. Install the two (2) nuts holding the inboard track to the upper support assembly lift links. Tighten to 27 Nm (20 lb-ft). See Figure 5.
14. Check to make sure the index marks on the inboard track C-channel and plastic-coated slide are still in alignment. The index marks on the inboard track C-channel and plastic-coated slide must align at this step. If the index marks do not match up, repeat Steps 10 through 12. See Figure 4.
15. Position the seat track in the vehicle. The left and right front mounting feet holes should align with the floor pan mounting holes, without pushing or pulling the seat track to force alignment. Check the witness marks (indentations) in the carpet. The tracks should line up closely with them. If the seat track does not align to the vehicle, check to make sure the index marks on the inboard and outboard track rails and guides are still in alignment. Repeat the necessary steps until the index marks align.
16. Install the connector bracket to the upper track support assembly (Taurus/Sable only).
17. Taurus/Sable - go back to steps 5 and 6 to properly install the seat track assembly back into the vehicle.
Thunderbird - go back to steps 5, 6 and 7 to properly install the seat track assembly back into the vehicle.