19 1995 Aerostar/Ranger/Explorer 9/15/2010 http://www
Contents
1. gt No GO to F3 F3 CHECK DRIVEN GEAR e Check for proper driven gear Refer to the Ford Speedometer Gear Supplement Charts for speedometer gear applications e lf odometer is accurate calibration of speedometer may be off Changing the speedometer may correct but going on to change either gear will make speedometer reading more accurate but now odometer will not be accurate e Is the correct driven gear installed gt Yes GO to F4 gt No REPLACE gear with correct gear CHECK for accuracy F4 CHECK DRIVE GEAR AXLE TIRES AND RATIO ADAPTOR e Check for proper drive gear axle tires and ratio adaptor e Is drive gear axle tire and ratio adapter correct gt Yes REPLACE Speedometer as described in Removal and Installation in this section CHECK for accuracy gt No REPLACE incorrect component or driven gear CHECK for accuracy PINPOINT TEST G SPEEDOMETER ODOMETER INOPERATIVE PSOM AEROSTAR G1 CHECK REAR ANTI LOCK LAMP ILLUMINATION e Key to RUN e Does anti lock lamp on dash go out after self test gt Yes GO to G2 display http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 9 15 2010 1995 Aerostar Ranger Explorer 19 gt No REFER to Section 06 09A for diagnosis of anti lock speed sensor and speed sensor gear G2 CHECK ODOMETER DISPLAY e ls odometer display on and do digits appear normal gt Yes GO to G3 gt No GO to G6 G3 CHECK FOR PRESENCE OF ER2. 570 BK W http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 9 15 2010 1995 Aerostar Ranger Explorer 19 e Measure resistances e Are resistances 5 ohms or less gt Yes GO to L3 gt No SERVICE Circuit 398 BK Y and 570 BK W for open RESTORE vehicle RETEST system L3 CHECK TACHOMETER INPUT CIRCUIT e Turn ignition switch to OFF position e Disconnect cluster Connector C1 e Disconnect ignition coil or DIS e Using an ohmmeter measure resistance of Circuit 11 T Y from ignition coil Connector or DIS Connector to cluster C1 Connector e Is resistance 1 8 ohms or less gt Yes GO to L4 gt No SERVICE Circuit 11 T Y for open RESTORE vehicle RETEST system L4 CHECK CLUSTER CLIP TO CLUSTER CIRCUIT CONNECTION e Reconnect cluster Connector C1 e Using an ohmmeter check for continuity from the tachometer connector clips to instrument cluster printed circuit e Is there continuity gt Yes GO to L5 gt No REPLACE connector clips RESTORE vehicle RETEST system L5 CHECK PRINTED CIRCUIT e Using an ohmmeter check each circuit listed below for continuity from gauge connector clips to cluster Connector J1 Pin ereun Function Ps foee exri Groua 640 R Y Run Start Power 11 T Y Tachometer Input e Is there continuity at all circuits gt Yes REPLACE speedometer tachometer assembly RESTORE vehicle RETEST system gt No REPLACE instrument cluster
3. Does the voltage increase smoothly and continuously from 0 to approximately 4 5 volts as vehicle speed increases from 0 to approximately 30 mph http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 9 15 2010 1995 Aerostar Ranger Explorer 19 OR e If available a frequency counter may be connected to Pin 7 speed out and Pin 2 module ground Does the displayed frequency of the signal increase smoothly and continuously from 0 to approximately 67 hz at approximately 35 mph OR e If neither a voltmeter nor frequency counter is available vehicle speed control may be used as a good indicator If it works normally above 30 mph this means that the speedometer module is at least receiving a speed input signal and the wiring and sensor can be assumed to be good Does speed control work gt Yes SERVICE wiring between speedometer and affected module as required VERIFY proper operation gt No GO to J3 J3 CHECK SPEED INPUT SIGNAL A CAUTION Make sure multimeter is in the voltage function and not in the resistance function to avoid damage to multimeter e Connect Rotunda Digital Volt Ohmmeter 014 00407 or equivalent to Pin 4 speed in and Pin 5 speed in Does the voltage increase smoothly and continuously from 0 to approximately 3 5 volts as vehicle speed increases from 0 to approximately 30 mph NOTE Only the wiring harness end of the connector should be probed OR e If available a frequen
4. 1995 Aerostar Ranger Explorer Section 13 01 Instrument Cluster Conventional DIAGNOSIS AND TESTING Pinpoint Tests PINPOINT TEST A FUEL LEVEL READS INACCURATELY A1 VERIFY POWER AT FUSE 11 LOAD SIDE e Key ON e Using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent verify system voltage at the load side of fuse 11 e Is the voltage greater than 10 volts gt Yes GO to A3 gt No GO to A2 A2 VERIFY POWER AT FUSE 11 FEED SIDE e Key ON e Using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent verify system voltage at the feed side of the fuse 11 e Is the voltage greater than 10 volts gt Yes REPLACE the fuse RETEST system gt No REPAIR the wiring to the fuse panel RETEST system A3 VERIFY POWER AT CLUSTER CIRCUIT 640 R Y e Have cluster connector s remain intact Partially remove the instrument cluster from the instrument panel e Key ON Measure the voltage on Circuit 640 R Y at the instrument cluster connector to ground e Is the voltage greater than 10 volts gt Yes GO to A4 gt No REPAIR Circuit 640 R Y RETEST system A4 VERIFY GROUND CIRCUIT 570 BK W 19 1995 Aerostar Ranger Explorer Workshop Manual A CAUTION Before checking the continuity of any circuit make sure there is no voltage present in the circuit prior to switching the test equipment to the resistance function to avoid damage to equipment Refer to the test equipment user s manual for a
5. REPLACE Vehicle Speed Sensor as described in Removal and Installation in this section CHECK speedometer for operation H5 CHECK GEARS e Check drive gear for damage or wear e Is drive gear damaged gt Yes REPLACE damaged or worn gear CHECK speedometer for operation gt No System OK PINPOINT TEST J SPEED CONTROL PCM OR ELECTRONIC TRANSMISSION INOPERATIVE OR ERRATIC NOTE Follow this procedure only after being referred here by the Speed Control PCM or electronic transmission shop manual diagnostics J1 CHECK REAR ANTI LOCK LAMP ILLUMINATION e Key ON e Does anti lock lamp on dash go out after self test gt Yes GO to J2 gt No REFER to Section 06 09A J2 CHECK SPEEDOMETER SPEED OUTPUT SIGNAL A CAUTION Before checking the continuity of any circuit make sure there is no voltage present in the circuit prior to switching the test equipment to the resistance function to avoid damage to equipment Refer to the test equipment user s manual for additional information e Using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent check for shorts in the wiring between Pin 7 speed out and battery ignition or ground Is circuit shorted e Use an ohmmeter to check for opens in the wiring between Pin 7 speed out and the affected module Verify that terminals in PSOM wiring connector are completely seated in the connector Is the circuit open e Connect an AC voltmeter to Pin 7 speed out and Pin 2 module ground
6. ROR MESSAGE NOTE ERROR 3 indicates the conversion constant must be programmed See Pinpoint Test E e Does the word ERROR appear on the odometer display gt Yes REPLACE Instrument Cluster as described in Removal and Installation in this section VERIFY proper operation gt No GO to G4 G4 CHECK ODOMETER OPERATION e Odometer display increments mileage with vehicle motion or rear wheels turning gt Yes GO to Gg gt No GO to G5 G5 CHECK SPEEDOMETER e Does speedometer indication increase with increasing vehicle speed gt Yes REPLACE Instrument Cluster as described in Removal and Installation in this section VERIFY proper operation gt No GO to Gs G6 CHECK SPEEDOMETER POWER FUSES e Remove check and reinstall battery power fuse No 8 if intact e Remove check and reinstall battery power fuse No 17 if intact NOTE If fuses are blown replace with a new intact fuse If new fuse blows determine cause and service as necessary e With fuses intact do the speedometer and odometer operate properly gt Yes REPLACE Instrument Cluster as described in Removal and Installation in this section VERIFY proper operation gt No Go to G7 G7 CHECK SPEEDOMETER CONNECTOR VOLTAGES e Verify battery ground and ignition available on Pins 1 2 and 3 respectively with key in RUN NOTE Only the wiring harness end of the connector should be probed http www fordtechservice dealerconnection com pubs conte
7. STER PRINTED CIRCUIT CONTINUITY A CAUTION Before checking the continuity of any circuit make sure there is no voltage present in the circuit prior to switching the test equipment to the resistance function to avoid damage to equipment Refer to the test equipment user s manual for additional information e Check for instrument cluster printed circuit continuity and confirm flex circuit to clip and clip to gauge contact by physically flexing the wiring and observing continuity Continuity reading should not fluctuate e Are wiring and instrument cluster printed circuit OK gt Yes REPLACE gauge as described in Removal and Installation in this section gt No Aerostar SERVICE wiring or REPLACE the Instrument Cluster as described in Removal and Installation in this section Ranger Explorer SERVICE wiring or REPLACE Instrument Cluster Printed Circuit as described in Removal and Installation in this section PINPOINT TEST E SPEEDOMETER ODOMETER READS INACCURATELY AEROSTAR E1 CHECK INITIAL STATUS e Refer to speedometer calibration tolerance specifications table in E7 Be sure to check the odometer calibration If both the odometer and speedometer are incorrect in the same direction it is usually a sign that the conversion constant tire size or speed sensor ring are different than programmed A speedometer inaccurate with an accurate odometer is usually a problem with the speedometer module itself e Are speedometer and odometer calib
8. Yes GO to A10 gt No SERVICE Circuit 29 Y W between the instrument cluster and the fuel gauge sending unit RETEST system A10 CHECK FUEL SENDING UNIT GROUND e Key OFF e Measure the resistance of Circuit 651 BK Y Ranger and Explorer or BK W Aerostar wire at the fuel gauge sending unit connector to ground at battery e Is the resistance less than 1 ohm gt Yes GO to A11 gt No SERVICE Circuit 651 BK Y Ranger and Explorer or BK W Aerostar wire from the fuel gauge sending unit to ground A11 CHECK FUEL GAUGE FULL Key OFF Disconnect the fuel gauge sending unit Connect one lead of the Rotunda Instrument Gauge System Tester 021 00055 or equivalent to Circuit 29 Y W at the fuel gauge sending unit connector and the other lead to ground Set the tester to 145 ohms e Key ON Wait one minute Read the fuel gauge Does the fuel gauge read F full http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 9 15 2010 1995 Aerostar Ranger Explorer 19 gt Yes GO to A13 gt No GO to A12 A12 CHECK INSTRUMENT CLUSTER GAUGE AMPLIFIER FULL e Turn the key to OFF position Remove the instrument cluster Inspect the instrument cluster printed circuit Remove the instrument cluster gauge amplifier Connect the jumper wire from the Rotunda Instrument Gauge System Tester 021 00055 or equivalent directly to the fuel gauge SIG terminal e Install the instrument cluste
9. cy counter may be connected to Pin 4 speed in and Pin 5 speed in Does the displayed frequency of the signal increase smoothly and continuously from 0 to approximately 667 hz at approximately 30 mph NOTE Only the wiring harness end of the connector should be probed gt Yes REPLACE Instrument Cluster as described in Removal and Installation in this section gt No SERVICE wiring CHECK for opens or shorted wiring If no problems are found REFER to Section 06 09A or Section 06 09B PINPOINT TEST K TACHOMETER INOPERATIVE RANGER AND EXPLORER K1 CHECK FUSE e Check fuse 11 e Is fuse OK gt Yes GO to K2 gt No REPLACE fuse If fuse blows again CHECK for short in circuit K2 CHECK CIRCUIT 11 T Y FOR VOLTAGE AT TACH TEST CONNECTOR e Start engine e Measure voltage at tach test connector using 73 Digital Multimeter 105 R0051 or equivalent e Is voltage between 0 3 and 0 6 volts Explorer or between 3 and 9 volts Ranger gt Yes GO to K3 gt No Refer to Powertrain Control Emission Diagnosis Manual Explorer OBDI or Ranger OBDII K3 CHECK CIRCUIT 640 R Y FOR VOLTAGE e Key off http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 9 15 2010 1995 Aerostar Ranger Explorer 19 Disconnect battery ground cable Remove instrument cluster Disconnect instrument cluster connector C1 Connect battery ground cable Key to RUN Check for battery voltage at instr
10. dditional information e Use an ohmmeter to check the continuity of the ground wire at the instrument cluster connector to ground e Is the resistance less than 1 ohm gt Yes GO to A5 gt No REPAIR Circuit 570 BK W RETEST system http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 9 15 2010 1995 Aerostar Ranger Explorer A5 CHECK FUEL GAUGE EMPTY e Key OFF e Disconnect the fuel gauge sending unit 19 e Connect one lead of the Rotunda Instrument Gauge System Tester 021 00055 or equivalent to the fuel sending unit input wire Circuit 29 Y W at the fuel gauge sending unit connector Connect the other lead to ground e Set the tester to 22 ohms e Key ON e Wait one minute e Read the fuel gauge Does the fuel gauge read E empty gt Yes GO to A9 gt No GO to A6 A6 RECHECK FUEL GAUGE EMPTY e Place the key in the OFF position Then to the ON position Tap on the instrument panel e Wait one minute e Read the fuel gauge e Does the fuel gauge read E empty gt Yes GO to A9 gt No GO to A7 A7 CHECK PRINTED CIRCUIT BOARD e Key OFF e Disconnect the instrument cluster and instrument cluster gauge amplifier e Measure the resistance of the circuit between the SIG terminal of the fuel gauge and the instrument cluster gauge amplifier e Is the resistance less than 1 ohm gt Yes GO to A8 gt No Ranger and Explorer REPLACE instrumen
11. e gt Yes GO to D4 gt No GO to D3 D3 VERIFY POWER AT FUSE PANEL FEED SIDE e Using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent verify system voltage at feed side of warning indicator fuse 11 e Is system voltage present at feed side of fuse gt Yes REPLACE fuse RETEST system gt No SERVICE wiring to fuse panel RETEST system D4 VERIFY POWER AT INSTRUMENT CLUSTER e Partially remove instrument cluster from instrument panel Using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent verify system voltage at cluster connector Circuit 640 R Y or gauge terminal e Is voltage present at instrument cluster connector and gauge terminal gt Yes GO to D5 gt No SERVICE Circuit 640 R Y D5 VERIFY GROUND CIRCUITRY AT INSTRUMENT CLUSTER A CAUTION Before checking the continuity of any circuit make sure there is no voltage present in the circuit prior to switching the test equipment to the resistance function to avoid damage to equipment Refer to the test equipment user s manual for additional information e Using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent check continuity of instrument cluster Circuit 570 BK W and gauge ground circuitry e Is ground circuitry good gt Yes GO to D6 gt No SERVICE Circuit 570 BK W http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 9 15 2010 1995 Aerostar Ranger Explorer 19 D6 CHECK INSTRUMENT CLU
12. e Inspect cluster connector for damage e Is voltage present at cluster connector and gauge terminal gt Yes GO to c4 gt No SERVICE Circuit 640 R Y RETEST system C4 VERIFY GROUND CIRCUITRY AT CLUSTER A CAUTION Before checking the continuity of any circuit make sure there is no voltage present in the circuit prior to switching the test equipment to the resistance function to avoid damage to equipment Refer to the test equipment user s manual for additional information e Using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent check continuity of instrument cluster Circuit 570 BK W and gauge ground circuitry e Is ground circuitry good gt Yes GO to C5 gt No SERVICE as required C5 TEST SENDER CIRCUIT AT LOW e Place key in the ON position with engine off Observe gauge performance e Does the gauge read L or below gt Yes GO to c6 gt No GO to C7 C6 CHECK GAUGE RESPONSE e Disconnect oil pressure switch and short the lead to engine ground e Does the gauge indicate approximately mid scale or slightly above mid scale around the MAL in NORMAL gt Yes REPLACE oil pressure switch REFER to Section 03 01A Section 03 01B or Section 03 01C gt No GO to c7 C7 CHECK SENDING UNIT SWITCH WIRING A CAUTION Before checking the continuity of any circuit make sure there is no voltage present in the circuit prior to switching the test equipment to the resistance function to avoid damage to
13. ead to sender ground Circuit 651 http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 9 15 2010 1995 Aerostar Ranger Explorer 19 BK Y e Move float rod slowly from FULL to EMPTY stop position e Does ohmmeter reading decrease slowly gt Yes GO to A17 gt No REPLACE fuel sender REFER to Section 10 01 A17 HARNESS CONNECTOR CHECK EMPTY STOP e Reattach all fuel indication connectors e Move float rod to empty stop position e Place key in the ON position e Wait 60 seconds e Read fuel gauge e Does fuel gauge read empty gt Yes GO to A18 gt No GO to A7 A18 HARNESS CONNECTOR CHECK FULL STOP Reattach all fuel indication connectors Move float rod to full stop position Place key in the ON position Wait 60 seconds Read fuel gauge Does fuel gauge read full gt Yes GO to A19 gt No GO to A7 A19 INSPECT FUEL SENDER e Inspect float and float rod e Is float rod distorted hitting filter filled with fuel or loose on float rod gt Yes REPLACE fuel sender REFER to Section 10 01 gt No GO to A20 A20 PIGTAIL HARNESS CHECK EXPLORER e Connect one lead of a Rotunda Digital Volt Ohmmeter 014 00407 or equivalent to the fuel sender signal lead Circuit 29 Y W in the pigtail connector and the other lead to the corresponding below the flange rivet e Check sending unit ground Circuit 651 BK Y in same manner as above e Is ohmmeter
14. equipment Refer to the test equipment user s manual for additional information e Using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent check sending unit switch wiring and instrument cluster printed circuit for shorts or opens by physically flexing the wiring and observing continuity The continuity reading should not fluctuate e Gauge will read beyond the normal band if not grounded e Is wiring and instrument cluster printed circuit OK gt Yes REPLACE gauge as described in Removal and Installation in this section gt No Aerostar SERVICE wiring or REPLACE the instrument Cluster Ranger Explorer SERVICE wiring or REPLACE Instrument Cluster Printed Circuit as described in Removal and Installation in this section PINPOINT TEST D CHARGE INDICATOR READS INACCURATELY http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 9 15 2010 1995 Aerostar Ranger Explorer 19 D1 VERIFY VOLTAGE GAUGE OPERATION e Key ON with engine stopped e Headlamps ON e Heater blower fan on HIGH e Does gauge pointer move toward the lower portion of the NORMAL BAND white marked area gt Yes GO to D2 gt No CHECK fuse 11 and the battery to circuit breaker and Circuit 640 R Y GO to D6 D2 VERIFY POWER AT FUSE PANEL LOAD SIDE e Using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent verify system voltage at load side of warning indicator fuse 11 e Is system voltage present at load side of fus
15. erage revs mile GO to E4 gt No Revs mile 20 850 TOD GO to E4 E7 RESET CONVERSION CONSTANT e Reprogram speed conversion constant using the following procedure Locate the dealer mode programming enable connection It is located behind the cowl side trim panel Insert metal clip in service wire panel connector Clip other end to vehicle ground while the key is in the OFF position Turn key to RUN not crank position while holding down the trip odometer RESET button on speedometer Release RESET button Speedometer will prove out sweep across dial and back The English Metric and revision levels will be displayed The last number on the right side of display is the reprogramming lockout count This count shows the number of allowable conversion constants remaining When the count is zero no additional changes can be made to this instrument cluster If a conversion constant change is necessary a service instrument cluster must be ordered Press and release RESET button again and PSOM conversion constant without the decimal point followed by the word CAL Press and release the odometer SELECT button as many times as necessary to change conversion constant to the correct value NOTE Pressing and releasing the RESET button to lock in the new conversion constant removes the number of times the PSOM can be reprogrammed by one count The module can only be reprogrammed six times If it is determined the original conversion constant is satisfacto
16. nt WSSK MUS LEN 20 9 15 2010 1995 Aerostar Ranger Explorer e Is resistance to ground less than 1 ohm with terminals in wiring harness connector completely seated in connector and locking tabs gt Yes REPLACE Instrument Cluster as described in Removal and Installation in this section gt No SERVICE wiring harness and fuses as required VERIFY proper operation G8 CHECK SPEED INPUT SIGNAL e Connect Rotunda Digital Volt Ohmmeter 014 00407 or equivalent to Pin 4 speed in and Pin 5 speed in NOTE Only the wiring harness end of the connector should be probed OR If available a frequency counter may be connected to Pin 4 speed in and Pin 5 speed in OR receiving a speed input signal and the wiring and sensor can be assumed to be good Does the speed control work normally gt Yes REPLACE Instrument Cluster as described in Removal and Installation in this section gt No SERVICE wiring CHECK for open or shorted wiring If no problems are found REFER to Section 06 09A G9 CHECK SPEEDOMETER OPERATION e Does speedometer indication increase with increasing vehicle speed gt Yes Normal operation ADVISE customer gt No REPLACE Instrument Cluster as described in Removal and Installation in this section PINPOINT TEST H SPEEDOMETER ODOMETER INOPERATIVE RANGER AND EXPLORER H1 CHECK CONNECTIONS e Verify connector is properly attached at speed sensor e Are connections good and is drive
17. pens by physically flexing the wiring and observing continuity The continuity reading should not fluctuate e Are wiring and flex circuit OK gt Yes REPLACE gauge as described in Removal and Installation in this section gt No Aerostar SERVICE wiring or REPLACE the Instrument Cluster as described in Removal and Installation in this section Ranger Explorer SERVICE wiring or replace Instrument Cluster Printed Circuit as described in Removal and Installation this section PINPOINT TEST C OIL PRESSURE READS INACCURATELY C1 VERIFY POWER AT FUSE PANEL LOAD SIDE e Using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent verify system voltage at load side of warning indicator fuse 11 e Is system voltage present at load side of fuse gt Yes GO to C3 gt No GO to C2 C2 VERIFY POWER AT FUSE PANEL FEED SIDE e Using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent verify system voltage at feed side of warning indicator fuse 11 e Is system voltage present at feed side of fuse gt Yes REPLACE fuse RETEST system gt No SERVICE wiring to fuse panel RETEST system C3 VERIFY POWER AT CLUSTER e Partially remove cluster from IP Using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent verify system voltage at cluster connector Circuit 640 R Y and or gauge terminal http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 9 15 2010 1995 Aerostar Ranger Explorer 19
18. printed circuit RESTORE vehicle RETEST system PINPOINT TEST M ALL WARNING INDICATORS INOPERATIVE M1 CHECK CLUSTER GROUND e Turn ignition switch to OFF position e Partially remove instrument cluster as outlined e Using an ohmmeter connected to a known good ground connect second lead to Circuit 57 BK at Connector C1 Pins 8 and 10 http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 9 15 2010 1995 Aerostar Ranger Explorer 19 e Measure resistance e Is resistance 5 ohms or less gt Yes GO to m2 gt No SERVICE Circuit 57 BK for open RESTORE vehicle RETEST system M2 CHECK SUPPLY AT CLUSTER e Turn ignition switch to RUN position e Using a test lamp check Clrcuit 640 R Y at Connector C1 e Did test lamp illuminate gt Yes REPLACE instrument cluster printed circuit RESTORE vehicle RETEST system gt No SERVICE Circuit 640 R Y for open RESTORE vehicle RETEST system http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 9 15 2010
19. r e Turn the key to the ON position e Read the fuel gauge e Does the fuel gauge read F full gt Yes REPLACE the Instrument Cluster Gauge Amplifier as described in Removal and Installation in this section GO to A5 gt No REPLACE the fuel gauge as described in Removal and Installation in this section RETURN toA5 A13 FUEL TANK INSPECTION e Inspect fuel tank for distortion or damage e Is fuel tank damaged gt Yes REPLACE fuel tank REFER to Section 10 01 gt No GO to A14 A14 TEST BOX CHECK EMPTY STOP e Connect one lead of a Rotunda Digital Volt Ohmmeter 014 00407 or equivalent to the fuel sender signal lead Circuit 29 Y W and the other lead to sender ground Circuit 651 BK Y e When the float rod is against the empty stop closest to fuel filter e Does DVOM read 14 18 ohms gt Yes GO to A15 gt No REPLACE fuel sender A15 TEST BOX CHECK FULL STOP e Connect one lead of a Rotunda Digital Volt Ohmmeter 014 00407 or equivalent to the fuel sender signal lead Circuit 29 Y W and the other lead to sender ground Circuit 651 BK Y e When the float rod is against the full stop e Does DVOM read 154 162 ohms gt Yes GO to A16 gt No less than 154 or greater than 162 ohms REPLACE fuel sender A16 TEST BOX CHECK FLOAT ROD TRAVEL e Connect one lead of a Rotunda Digital Volt Ohmmeter 014 00407 or equivalent to the fuel sender signal lead Circuit 29 Y W and the other l
20. ration within specified limits gt Yes Speedometer normal gt No GO to E2 E2 CHECK FOR NOT PROGRAMMED MESSAGE e Does ERROR 3 message alternate with normal odometer display gt Yes GO to E7 RESET conversion constant REFER to Reset Conversion Constant in E7 gt No GO to E3 E3 CHECK TIRES AXLE CAPACITY e Are tires the same size on opposite ends of a common axle and properly inflated gt Yes DETERMINE conversion constant GO to E5 gt No CORRECT condition or ADVISE customer GO to E1 E4 VERIFY CONVERSION CONSTANT AND DISPLAY MODE e Check whether the conversion constant in the speedometer is correct with the following procedure Press and hold the RESET button on the front of the speedometer while turning the key to RUN Release the RESET button The pointer will prove out and some codes will appear on the odometer display If an E is on the left side of the display the module is programmed for English display mode and should have English MPH graphics A lower case o signifies an overseas KMH graphics Verify the graphics and display modes agree The number appearing after the type is the microprocessor revision level and is not used in this test Press and release the RESET button again The conversion constant and the word CAL will be shown on the odometer display Verify the programmed conversion constant is the same as that displayed on the chart or the constant calculated in E6 Refer to Conver
21. reading greater than 1 ohm http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 9 15 2010 1995 Aerostar Ranger Explorer 19 gt Yes REPLACE fuel sending unit REFER to Section 10 01 gt No Pigtail OK PINPOINT TEST B COOLANT TEMPERATURE READS INACCURATELY B1 VERIFY POWER AT FUSE PANEL LOAD SIDE e Using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent verify system voltage at load side of warning indicator fuse 11 e Is system voltage present at load side of fuse gt Yes GO to B3 gt No GO to B2 B2 VERIFY POWER AT FUSE PANEL FEED SIDE e Using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent verify system voltage at feed side of warning indicator fuse 11 e Is system voltage present at feed side of fuse gt Yes REPLACE fuse RETEST system gt No SERVICE wiring to fuse panel RETEST system B3 VERIFY POWER AT INSTRUMENT CLUSTER e Partially remove cluster from instrument panel Using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent verify system voltage at cluster connector Circuit 640 R Y or gauge terminal e Inspect cluster connector for damage e Is voltage present at cluster connector and gauge terminal gt Yes GO to B4 gt No SERVICE Circuit 640 R Y RETEST system B4 VERIFY GROUND CIRCUITRY AT CLUSTER A CAUTION Before checking the continuity of any circuit make sure there is no voltage present in the circuit prior to swi
22. ry turn the key to OFF BEFORE the new constant is locked in When the correct new value is displayed in odometer window press and release the RESET button to lock in the new conversion constant Turn the key off and remove the ground wire Verify proper operation of the speedometer e Is conversion constant set to desired value Actual Speedometer or Odometer Value 48 km h 30 mph Actual 97 km h 60 mph Actual Odometer Measure Over Actual 16 1 km Distance 10 Indicated Speed Speed Miles Allowable Range 45 55 km h 93 108 km h 15 4 16 6 km 28 34 mph 58 67 mph 9 6 10 3 miles gt Yes Procedure complete gt No GO to E5 http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 9 15 2010 1995 Aerostar Ranger Explorer 19 PINPOINT TEST F SPEEDOMETER ODOMETER READS INACCURATELY RANGER AND EXPLORER F1 CHECK CONNECTIONS e Verify connector is properly attached at speed sensor e Are all connections good gt Yes GO to F2 gt No REPAIR or REPLACE as necessary RETEST system F2 CHECK ODOMETER e Check accuracy of odometer e If odometer is accurate calibration of speedometer may be off Changing the speedometer may correct but going on to change either gear will make speedometer reading more accurate but now odometer will not be accurate e ls odometer accurate gt Yes REPLACE Speedometer as described in Removal and Installation in this section CHECK for speedometer accuracy
23. sion Constants Chart under Specifications in this section Turn off the key to exit this test e Is the programmed conversion constant the same as that displayed on the chart or the constant calculated in E6 gt Yes REPLACE Instrument Cluster as described in this section VERIFY proper operation gt No http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 9 15 2010 1995 Aerostar Ranger Explorer 19 GO to E7 E5 DETERMINE CONVERSION CONSTANT e Check tire size and type on vehicle rear axle or SAE average revs mile Refer to Tire Axle Capacity Chart and note conversion constant e Can the conversion constant be determined gt Yes VERIFY conversion constant GO to E4 gt No GO to E6 E6 MEASURE TIRE DIAMETER e To determine the conversion constant perform the following procedure Hoist vehicle Measure tire outside diameter TOD Note number of rear axle speed sensor teeth speed sensor ring diameter or axle capacity tape group Verify speed sensor ring diameter with identification tag attached to rear axle cover retaining bolts If tag is missing manually count teeth NOTE 7 5 inch rear axles have 102 teeth and 8 8 inch rear axles have 108 teeth e ls outside diameter greater than 25 2 inches S STERLING PLANT PLANT CODE 5832F MONTH wal DAY 355 1025 A A Bi AXLE RING GEAR RATIO DIAMETER 6469 E gt Yes USE formula revs mile 1528 28x TOD to calculate SAE av
24. t cluster printed circuit as described in Removal and Installation Instrument Cluster in this section Aerostar REPLACE instrument cluster as described in Removal and Installation Instrument Cluster in this section A8 CHECK INSTRUMENT CLUSTER GAUGE AMPLIFIER EMPTY e Turn the key to OFF position Remove the instrument cluster Inspect the instrument cluster printed circuit e Remove the instrument cluster gauge amplifier Connect a jumper wire from the Rotunda Instrument Gauge System Tester 021 00055 or equivalent directly to the fuel gauge SIG terminal e Install the instrument cluster e Turn the key to the ON position e Read the fuel gauge e Does the fuel gauge read E empty http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 9 15 2010 1995 Aerostar Ranger Explorer 19 K19253 B gt Yes REPLACE the Instrument Cluster Gauge Amplifier as described in Removal and Installation in this section GO to A5 gt No REPLACE the fuel gauge as described in Removal and Installation in this section INSTALL the Instrument Cluster Gauge Amplifier as described in Removal and Installation in this section and RETURN to A5 A9 CHECK FUEL GAUGE SENDING UNIT WIRE e Key OFF e Disconnect the instrument cluster and the fuel gauge sending unit e Measure the resistance of Circuit 29 Y W between the instrument cluster and the fuel gauge sending unit e Is the resistance less than 1 ohm gt
25. tching the test equipment to the resistance function to avoid damage to equipment Refer to the test equipment user s manual for additional information e Using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent check continuity of cluster and gauge ground Circuit 570 BK W e Is the resistance less than 1 ohm gt Yes GO to B5 gt No SERVICE Circuit 570 BK W RETEST system B5 TEST SENDER CIRCUIT AT COLD e Insert Rotunda Instrument Gauge System Tester 021 00055 or equivalent Disconnect connector at sender and connect tester to cluster side of connector Circuit 39 R W Set to 74 ohms http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 9 15 2010 1995 Aerostar Ranger Explorer 19 e Does gauge read C gt Yes GO to B6 gt No GO to B7 B6 TEST SENDER CIRCUIT AT HOT e Set Gauge System Tester to 9 7 ohms e Does gauge read H gt Yes REPLACE coolant temperature sender REFER to Section 03 03 gt No GO to B7 B7 CHECK SENDING UNIT CIRCUIT WIRING A CAUTION Before checking the continuity of any circuit make sure there is no voltage present in the circuit prior to switching the test equipment and to the resistance function to avoid damage to equipment Refer to the test equipment user s manual for additional information e Using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent check sending unit circuit wiring and instrument cluster printed circuit for shorts or o
26. tip seated properly gt Yes GO to H2 gt No SERVICE or REPLACE as necessary RETEST system H2 CHECK ODOMETER POINTER e Check operation of odometer pointer e Does the odometer operate and the speedometer pointer not operate gt Yes GO to H3 gt No REPLACE Speedometer as described in Removal and Installation in this section RECHECK speedometer for operation http www fordtechservice dealerconnection com pubs content WSSK MUS LEN 20 Does the voltage increase smoothly and continuously from 0 to approximately 3 5 volts as vehicle speed increases from 0 to 30 mph Does the displayed frequency of the signal increase smoothly and continuously from 0 to approximately 667 Hz at approximately 30 mph 19 If neither a voltmeter nor frequency counter is available vehicle speed control may be used as a good indicator If it works normally then the speedometer module is at least 9 15 2010 1995 Aerostar Ranger Explorer 19 H3 CHECK SPEEDOMETER POINTER e Check operation of speedometer pointer e Does the speedometer pointer operate gt Yes GO to H4 gt No REPLACE Speedometer as described in Removal and Installation in this section RECHECK speedometer for operation H4 CHECK VEHICLE SPEED SENSOR e Disconnect speedometer connector from vehicle speed sensor and remove vehicle speed sensor and check that shaft in vehicle speed sensor turns freely e Does shaft turn freely gt Yes GO to H5 gt No
27. ument cluster connector pin C1 4 using digital multimeter Is battery voltage present gt Yes GO to K4 gt No REPAIR Circuit 640 R Y VERIFY tachometer operation K4 CHECK GROUND CIRCUIT RESISTANCE e Key off e Measure resistance between instrument cluster connector Pin C1 1 and chassis ground using digital multimeter e Is resistance less than 5 ohms gt Yes GO to K5 gt No REPAIR ground Circuit 398 BK Y or 57 BK VERIFY tachometer operation K5 CHECK INSTRUMENT CLUSTER PRINTED CIRCUIT e Visually inspect instrument cluster printed circuit e Is printed circuit OK gt Yes REPLACE Tachometer REFER to Removal and Installation portion of this section VERIFY tachometer operation gt No REPLACE printed circuit REFER to Removal and Installation portion of this section VERIFY tachometer operation PINPOINT TEST L TACHOMETER NOT REFLECTING ENGINE SPEED L1 CHECK SUPPLY TO GAUGE e Turn ignition switch to OFF position e Partially remove instrument cluster panel as outlined to gain access to the cluster connectors e Turn ignition switch to the RUN position e Using a voltmeter check voltage at Circuit 640 R Y at connector e Is battery voltage present gt Yes GO to L2 gt No SERVICE Circuit 640 R Y for open RESTORE vehicle RETEST system L2 CHECK GAUGE GROUND e Using an ohmmeter connected to a known good ground connect second lead to Circuit 398 BK Y except Ranger 2 3L and Circuit
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