Instrument Panel

INSTRUMENT PANEL

Exploded View

Taurus, Sable (Part 1):

Taurus, Sable (Part 2):

Taurus X (Part 1):

Taurus X (Part 2):

Removal
1. Remove the front seats. Service and Repair
2. Remove the selector lever. Shifter A/T
3. Drain the cooling system. Service and Repair
4. Recover the refrigerant. Service and Repair
5. Remove the wiper mounting arm and pivot shaft assembly. Wiper Arm
6. Remove the 2 nuts and the PCM.
- Disconnect the 3 PCM electrical connectors.







7. Remove the 3 nuts and the PCM bracket.







8. Remove the vacuum hose clip from the cowl.







9. Remove the strut tower cross brace.
- Remove the 2 LH and 2 RH strut upper mount nuts.







10. Remove the RH instrument panel upper cowl bolt.







11. Remove the 2 LH instrument panel upper cowl bolts.







12. Disconnect the vacuum hose and the evaporator purge solenoid hose from the upper intake manifold.







13. Remove the thermostatic expansion valve (TXV) manifold.
- Remove the TXV manifold bolt.
- Discard the O-rings seals.







14. Disconnect the heater hoses.







15. Remove the RH and LH front door weatherstrips.

16. NOTE: Right side shown, left side similar.

Position the RH and LH scuff plate trim panels aside.
- Pull the front of the scuff plate trim panels upward to release the retaining clips.







17. NOTE: Right side shown, left side similar.

Remove the RH and LH lower cowl trim panels.
- Pull the panel rearward to release it from the clips.







18. Remove the 2 pushpin retainers and the lower instrument panel insulator.







19. Remove the driver footrest pad.
- Remove the 2 pin-type retainers.







20. Remove the LH and RH front carpet sections.
- Remove the 2 pin-type retainers.

21. Disconnect the RH main wiring harness electrical connector and radio antenna connector.







22. If equipped, remove the 2 pin-type retainers and the rear footwell duct.







23. Remove the 2 bolts and the ground wires from the floor pan tunnel.







24. Remove the RH and LH instrument panel side panels.







25. Remove the RH and LH A-pillar trim panels. Trim Panel
- Pull the top outboard edge of the A-pillar trim panel toward the inside of the vehicle to disengage the retaining clips.
- Pull the A-pillar trim panel upward to remove it from the dash panel.

26. Remove the 3 bolts and the steering column cover.







27. Position the hood release handle aside.
- Remove the 2 screws.







28. Rotate the steering wheel to gain access to the steering column shaft-to-steering column bolt.
29. Remove and discard the steering column shaft-to-steering column bolt.







30. Rotate the steering wheel until the front wheels are in the straight-ahead position.
- Remove the ignition key.

31. CAUTION: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring may result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered.

Detach the upper steering column shaft from the steering column.

32. Disconnect the LH side main wiring harness electrical connector.







33. Disconnect the 2 smart junction box (SJB) electrical connectors.







34. Remove the wire harness pin-type retainer from the SJB
35. If equipped, disconnect the electrical connector located on the steering column opening bracket.







36. Disconnect the restraints control module (RCM) small electrical connector.







37. Disconnect the stability control sensor cluster electrical connector.







38. Remove the 4 instrument panel center support bolts.

39. CAUTION: To avoid damaging the instrument panel, an assistant is required when carrying out this step.

NOTE:
- Mark the location of the instrument panel side bolts for correct alignment upon installation.
- Remove the bolts from one side completely and support the instrument panel before removing the bolts from the opposite side.

Remove the 6 instrument panel side bolts.

40. NOTE: Make sure that all electrical connectors and wiring are not hindered before removing the instrument panel.

Remove the instrument panel.
- Rotate the instrument panel face down and remove through the right door.







Installation

1. CAUTION: To avoid damage to the instrument panel, an assistant is required when carrying out this step.

NOTE: Make sure that all electrical connectors and wiring are correctly routed when installing the instrument panel.

Install the instrument panel.

2. NOTE: Align the instrument panel side bolts with the instrument panel side bolt markings.

Install, but do not tighten, the following:
- 6 instrument panel side bolts.
- 4 instrument panel center support bolts.
- 3 instrument panel upper cowl bolts.

3. Tighten the 6 instrument panel side bolts.
- Tighten to 40 Nm (30 lb-ft).

4. Tighten the 4 instrument panel center support bolts.
- Tighten to 25 Nm (18 lb-ft).

5. Tighten the 3 instrument panel upper cowl bolts.
- Tighten to 25 Nm (18 lb-ft).

6. Connect the stability control sensor cluster electrical connector.







7. Connect the small RCM electrical connector.







8. If equipped, connect the electrical connector located on the steering column opening bracket.







9. Connect the 2 SJB electrical connectors.







10. Install the wire harness pin-type retainer onto the SJB.
11. Connect the LH side main wiring harness electrical connector.







12. CAUTION: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring may result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered.

Install the upper steering column shaft to the steering column.

13. Rotate the steering wheel to gain access to the steering column shaft-to-steering column bolt.
14. Install a new steering column shaft-to-steering column bolt.
- Tighten to 25 Nm (18 lb-ft).







15. Rotate the steering wheel until the front wheels are in the straight-ahead position.
16. Install the hood release handle and tighten the 2 screws.







17. Install the steering column cover and the 3 bolts.







18. Install the RH and LH A-pillar trim panels. Trim Panel
19. Install the RH and LH instrument panel side panels.







20. Install the ground wires and the 2 bolts to the floor pan tunnel.







21. If equipped, install the rear footwell duct and the 2 pin-type retainers.
22. Connect the RH main wiring harness electrical connector and the radio antenna connector.







23. Install the LH and RH front carpet sections.
- Install the 2 pin-type retainers.

24. Install the driver footrest pad.
- Install the 2 pin-type retainers.







25. Install the lower instrument panel insulator and the 2 pushpin retainers.







26. Install the RH and LH lower cowl trim panels.
27. Install the RH and LH scuff plate trim panels.
28. Install the RH and LH front door weatherstrips.
29. Connect the heater hoses.







30. Install the TXV manifold and the TXV manifold bolt.
- Install new O-rings seals.
- Tighten to 8 Nm (71 lb-in).







31. Connect the vacuum hose and the evaporator purge solenoid hose to the upper intake manifold.







32. Install the strut tower cross brace.
- Install the LH and RH strut upper mount nuts
- Tighten to 30 Nm (22 lb-ft).







33. Install the vacuum hose clip onto the cowl.







34. Install the PCM bracket and the 3 nuts.







35. Install the PCM and the 2 nuts.
- Connect the 3 PCM electrical connectors.







36. Install the wiper mounting arm and pivot shaft assembly. Wiper Arm
37. Charge the refrigerant. Service and Repair
38. Fill the cooling system. Service and Repair
39. Install the selector lever. Shifter A/T
40. Install the front seats. Service and Repair