DisclaimerTechnical Service Bulletin # 10C11S1 Date: 100429
Important Information
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For VIN/Part Number Applications, please contact Dealer.
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Attachment I - Administrative Information OASIS ACTIVATED?
Yes, OASIS will be activated on April 19, 2010-2020.
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website on April 19, 2010-2020. Owner names and addresses will be available by May 28, 2010-2020.
NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall.
STOCK VEHICLES
Correct all affected units in your new vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this recall.
RELATED DAMAGE
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If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
Refunds are not authorized for this program.
RENTAL VEHICLES
With proper parts ordering and service appointment scheduling, rental vehicles should not be required. The Recliner Replacement Reference Tables (Attachment VI and VII) have been provided to assist. However, if you have a unique circumstance which may require a rental vehicle, please contact the Special Service Support Center.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center.
^ Refer to Attachment VI and VII for specific VIN Labor Operation information if needed.
^ Claiming information for Hog Rings (Submit on same repair line as repair).
- Program Code: 10C11
- Misc. Expense: OTHER
- Misc. Expense: $0.25 Attachment II - Labor and Parts Information LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
To manage part availability, dealers must contact the Special Service Support Center Parts Order Line. Dealers will receive a DOES II message when part requirements can be ordered through normal order processing channels.
When calling to place an order for a parts kit, please be prepared to provide:
^ Dealer P&A Code VIN
The DOR/COR number for this recall is 50419.
Questions regarding parts should be directed to the Special Service Support Center Parts Order Line or E-mailed.
DEALER PRICE
For latest prices, refer to DOES II.
PARTS RETENTION AND RETURN
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Affected manual recliners or backrest frames are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions.
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. 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:
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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.
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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:
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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.
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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.
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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:
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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.
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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.
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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.
Attachment IV - Fusion and Milan - Driver 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 IV
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FUSION AND MILAN - DRIVER SEAT BACKREST FRAME 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. Push the release buttons on the head restraint guide sleeves and remove the head restraint
2. 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.
3. Depower the Supplemental Restraint System (SRS) For additional information, refer to the WSM, Section 501 20B, SRS Depowering Procedure.
4. Remove the four seat track-to-floor bolt covers and the bolts.
5. Lift the seat to disengage the two forward locators from the floor and tip the seat rearward to access the seat harness electrical connectors.
6. 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.
7. Disconnect the electrical connector.
Disassembly
All Seats
7. If equipped with manual height adjust, remove the handle cover and the screws Pull outward on the handle to remove See Figure 1.
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8. Position the seat cushion away from the side shield. Remove and discard the manual recliner handle spring clip (See Figure 2). Remove and discard the manual recliner handle by pulling outward on the handle.
9. If equipped with manual lumbar, adjust the lumbar support to the fully relaxed position by turning the control knob clockwise. Using a suitable tool, remove and discard the control knob. See Figure 3.
10. If equipped with a power seat using a suitable trim tool, remove the seat control switch knob. See Figure 4.
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11. Remove and discard the side shield from the seat cushion frame. See Figure 5.
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.
12 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 RH recliner Separate the hook-and-loop from the safety belt buckle. See Figure 6.
13. NOTE: For proper routing during assembly note the routing of the side air bag module wire harness and the pin-type retainers.
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Release one of the seat cushion trim cover J-clips from the rear of the seat cushion frame Disconnect the side air bag wire harness electrical connector and carefully release the three pin-type retainers using a suitable trim tool See Figure 7.
Seats Equipped With Manual Lumbar
14. NOTICE: Make sure not to damage the manual lumbar control when drilling out the rivets. The manual lumbar control will be reused.
NOTE: To help prevent the body of the rivet from spinning while drilling hold the drill at a 45° angle on the head of the rivet and rotate the drill in a circular motion using short bursts.
Using a suitable trim tool, release the power seat wire harness pin-type retainer from the seat cushion frame. Use a low speed drill with a 13/64 in. (5 mm) drill bit and carefully drill off the heads of the two manual lumbar control retaining rivets. See Figure 8.
15. NOTICE: Make sure not to damage the manual lumbar control when punching the rivet body through the seat cushion frame. The manual lumbar control will be reused.
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Using a 1/8 in. (3 mm) punch, carefully remove the rivet bodies from the manual lumbar control/seat cushion frame. See Figure 9.
16. Disconnect the manual lumbar control from the cable. See Figure 10.
17. Using a low speed drill with a 11/64 in (4.37 mm) drill bit, enlarge the manual lumbar control rivet holes for the installation of the new rivets.
18. NOTE: For proper routing during assembly, note the routing of the manual lumbar cable and the pin-type retainers.
Release and discard the manual lumbar cable pin-type retainers from the seat cushion frame.
All Seats
19. Remove and discard the four recliner-to-seat cushion frame bolts and separate the seat backrest from the seat cushion frame. See Figure 11.
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NOTE RH side shown, LH side similar
20. Remove and discard both of the head restraint guide sleeves by positioning a 3/16 in. (5 mm) flat- blade 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 12.
NOTE: The seat backrest trim cover and foam pad are removed for clarity.
NOTE: Typical head restraint guide sleeve shown, others similar.
21. WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body Do not set a live air bag module down with the deployment door/trim cover/tear seam face down Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment.
WARNING: If the seat side air bag cover has been damaged or separated from its mounting, or if the air bag material has been exposed, install a new seat side air bag module Never try to repair the seat side air bag module Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash.
NOTICE: Make sure not to damage the tethered side air bag module bolt cover during removal.
Using a suitable trim tool, open the tethered side air bag module bolt cover and remove the bolt. Remove the side air bag module by carefully lifting upward and outward from the seat backrest frame. Disconnect the electrical connector.
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22. Remove and discard the two pin-type retainers Disconnect the backrest trim cover flaps from both of the recliners. See Figure 13.
23. Remove and discard the first row of hog rings from the listing wire on the backrest foam pad. See Figure 14.
1. Release the backrest trim cover lower J-clip and release the hook-and-loop strips.
2. Fold the backrest trim cover back to access and remove the first row of hog rings.
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24. Release the additional hook-and-loop strips and invert the backrest trim cover to gain access to the upper hog rings. Remove and discard the upper hog rings. See Figure 15.
25. Separate and remove the foam pad from the backrest frame.
26. Remove the lumbar assembly by squeezing the sides of the clips together. See Figure 16.
NOTE: Manual lumbar is shown static lumbar is similar.
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27. Remove the two side air bag module mounting bracket nuts and bracket. Discard the backrest frame. See Figure 17.
Assembly
All Seats
28. Install the side air bag module mounting bracket to the new backrest frame using the two nuts. See Figure 17.
^ Tighten to 8 Nm (70 lb-in).
29. Install the lumbar assembly onto the new backrest frame by squeezing the sides of the lumbar spring clips together.
30. Install the new side air bag module wire harness and the three pin-type retainers onto the new backrest frame as previously noted.
31. Install the backrest foam pad onto the new backrest frame.
32. NOTE: When installing the new upper row of hog rings position the hog rings onto 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.
1. Position the backrest trim cover onto the backrest foam pad/new backrest frame.
2. Using suitable hog ring pliers attach the new upper hog rings to the listing wire.
3. Roll the backrest trim cover down and attach the hook-and-loop strips
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33. NOTE: When installing the new first row hog rings position the hog rings onto the listing wire first.
Install the new first row hog rings. See Figure 18.
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.
34. Attach the backrest trim cover flaps to both of the recliners with the new pin-type retainers. See Figure 13.
35. NOTE: Make sure that the side air bag module locator hook engages into the mounting bracket. Install the side air bag module.
1. Connect the side air bag module electrical connector.
2. Position and hook the side air bag module onto the new seat backrest frame.
3. Install the side air bag module bolt. Tighten to 10 Nm (89 lb-ft).
4. Close the tethered side air bag module bolt cover.
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.
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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 19.
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 19.
38. To install the new head restraint guide sleeves, slide the sleeves through the backrest trim cover and the foam pad Using a back and forth motion while twisting, apply downward pressure until the sleeve is seated onto the new backrest frame as far as it will go. See Figure 20.
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39. Using a non-marring 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 21.
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)
^ Tighten to 55 Nm (41 lb-ft)
Seats Equipped With Manual Lumbar
42. Attach the manual lumbar cable pin-type retainers to the seat cushion frame.
43. Connect the manual lumbar control to the cable.
44. Using a suitable rivet gun, install the manual lumbar control onto the seat cushion frame with two new rivets. See Figure 22.
45. Attach the power seat wire harness pin-type retainer and harness onto the seat cushion frame.
All Seats
46. Connect the side air bag module electrical connector. Position the harness to the previously noted location and attach the three pin-type retainers. See Figure 23.
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47. Clip the first seat cushion trim cover J-clip to the rear of the seat cushion frame.
48. 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 RH recliner.
49. If equipped with a power seat install the seat control switch into the new side shield and connect the seat control switch electrical connector.
50. Install the new side shield onto the seat cushion frame.
1. Attach the side airbag wire harness locator onto the new side shield.
2. Align the retainers with the seat cushion frame apply pressure on the middle and the rear of the side shield and snap into place.
51. If equipped with a power seat install the seat control switch knob by gently pushing until it completely seats.
52. If equipped with manual lumbar, install the new control knob by firmly pushing until an audible click is heard.
53. Install the new manual recliner handle by applying pressure until fully seated onto the new manual recliner.
54. If equipped with manual height adjust, install the handle by pushing inward.
Install the two screws and the cover.
Installation
Manual Seats
55. To synchronize the seat tracks, align both track rails with the rear edge of the seat track base.
All Seats
56. Position the seat into the vehicle.
57. Connect the seat electrical connectors.
1. Make sure the assurance lever of the electrical connector is in the fully released position.
2. Connect the 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.
58. 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.
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2. Install by hand all four seat track-to-floor bolts, then tighten. See Figure 24.
^ Tighten to 47 Nm (35 lb-ft) in the following sequence.
3. Install the four seat track-to-floor bolt covers.
59. Install the head restraint into the head restraint guide sleeves
60. Repower the Supplemental Restraint System (SRS). For additional information, refer to WSM, Section 501-20B, SRS Repowering Procedure. 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
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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.
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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
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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.
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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.
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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.
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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).
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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.
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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.
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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
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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Technical Service Bulletin # NHTSA10V161000 Date: 100416
Recall 10V161000: Front Seat Manual Recliner Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Explorer 2010-2020
Ford/Explorer Sport Trac 2010-2020
Ford/Fusion 2010-2020
Mercury/Milan 2010-2020
Mercury/Mountaineer 2010-2020
MANUFACTURER: Ford mOtor Company
MFR'S REPORT DATE: April 16, 2010-2020
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NHTSA CAMPAIGN ID NUMBER: 10V161000
NHTSA ACTION NUMBER: N/A
COMPONENT: Seats: Front Assembly: Recliner
POTENTIAL NUMBER OF UNITS AFFECTED: 33256
SUMMARY: Ford is recalling certain model year 2010-2020 Fusion, Explorer, Explorer Sport Trac, and Mercury Milan and Mountaineer vehicles manufactured between December 15, 2009 through February 3, 2010-2020 equipped with front seat manual recliners. These vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 202, "Head Restraint." The recliner gear plate teeth may be out of dimension specification which could result in limited pawl to gear plate tooth engagement.
CONSEQUENCE: In the event of a crash, the seatback and head restraint may move rearward, increasing the risk of injury.
REMEDY: Dealers will replace the manual recliners for both power and manual seats free of charge. The safety recall is expected to begin on or before April 30, 2010-2020. Owners may contact Ford at 1-866-436-7332.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.Technical Service
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