Ford FCS-14000-DL GPS Receiver User Manual
Contents
1. N0016848 i d Seating Cam Followers Care should be taken to ensure that the remaining followers are properly seated prior to camshaft installation 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 33 LESSON 3 POWERTRAIN N0016849 Phaser Pin and Cam Notch Item Description Item Description 1 Phaser Pin 2 Cam Notch It is extremely important to align the phaser pin with the camshaft end notch NOTE If these are not aligned during installation the phaser and camshaft will be damaged 3 34 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN E N0016845 Installing the Bearing Caps Install the camshaft bearing caps in the reverse order of removal NOTE The camshaft bearing caps must be installed in their original locations The front thrust cap should be installed last to prevent the cap from breaking Next install the phaser bolt by hand Remove the timing chain wedge Rotate the crankshaft pulley counter clockwise back to the 12 o clock position NOTE Tighten the phaser bolt to 40 Nm 30 Ib ft plus 90 degrees 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 35 LESSON 3 POWERTRAIN Electronic Engine Controls N0015683 Electronic Engine Controls New integrated 4x4 strategy 4x4 operational strategy is now incorporated into the PCM This eliminates the nee2. N0015698 Transmission Control Module TCM The TCM is mounted on top of the main control valve body The control module has been designed to operate correctly in the environment in which the TCM is located The TCM is activated and deactivated by the ignition supply and is connected to the transmission link harness by a 16 pin connector The TCM monitors all TCM inputs and outputs to confirm correct system operation If a fault occurs the TCM is able to carry out default action It informs the driver of the problem through the instrument cluster message center The TCM is programmable The WDS can be used to flash selected program strategies within the TCM 3 54 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN Solenoids N0015699 Solenoids Item Description Item Description 1 SSA EDS1 3 SSD EDS4 2 SSB EDS2 6 SSE MV1 3 SSC EDS3 7 TCC EDS6 4 PCA EDS5 The hydraulic module contains one solenoid valve The solenoid valve is activated by the TCM and is either open or closed It is used to switch the position valve There are six electronic pressure control valves which convert an electronic current into a proportional hydraulic pressure They are energized by the TCM and actuate the valves belonging to the relevant switching elements The TCM monitors each pressure regulator and solenoid for open and short circuits The TCM al
3. Exhaust a Intake e Intake Remove Only the Indicated Followers When removing the followers remove the exhaust followers from the exhaust manifold side of the camshaft and the intake followers from the intake side On the right side 1 cylinder exhaust only 4 cylinder both intake On the left side 8 cylinder exhaust only 5 cylinder both intake Use ESST 303 1039 Valve Spring Compressor 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 27 LESSON 3 POWERTRAIN N0015757 Set Crankshaft Damper Spoke to 6 o clock Position Rotate the marked damper spoke clockwise to the 6 o clock position A CAUTION It is imperative that the engine is only rotated to the 6 o clock position in a clockwise rotation NOTE The only time the engine is turned counter clockwise back to the 12 o clock keyway position is during the re assembly procedure 3 28 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN N0016844 Inset Timing Chain Wedge Tool Assemble the ESST 303 636 Timing Chain Wedge to the ESST 303 637 Handle Insert the timing chain wedge tool between the chain spans Four to six clicks will hold it Mark the chain to the phaser for reinstallation The R on the right phaser and the L on the left that was used on the 2004 F 150 is no longer used 2005 Expedition Navigat
4. The fuel filter is located on the front side of the fuel tank It can be accessed by removing the road debris shield Quick connect fittings are used for connection to the fuel lines The fuel tank sending unit tool SST310 123 is required to service the fuel pump and or sending unit This tool was released as part of the 2004 F 150 tool kit 3 38 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN Engine Special Service Tools a N0017764 Engine Special Service Tools Item Description Item Description 1 ESST 307 516 1 Installer Teflon Seal 7 ESST 310 123 Remover Installer Tank 4R75E Tool Sender Unit 2 ESST 307 516 2 Installer Teflon Seal 8 ESST 205 086 1 Adaptor for 205 086 4R75E Tool 3 ESST 307 516 3 Installer Teflon Seal 9 ESST 418 F395 Diagnostic Service 4R75E Tool Tool Restraint System 4 ESST 307 516 4 Installer Teflon Seal 10 ESST 303 1046 Locking Tool Cam 4R75E Tool Phaser 5 ESST 310 122 Fuel Pressure Gauge 11 ESST 303 1040 Alignment Pins Connector Cylinder Head 6 ESST 303 1039 Compressor Valve Spring 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 39 LESSON 3 POWERTRAIN Automatic Transmission Description N0015685 6HP26 Transmission The 6HP26 transmission uses planetary gears with multiple clutches and electronic controls The Transmission Control Module TCM and the main control valv
5. Improved low speed performance torque and high speed operation horsepower Enhanced idle quality Lower exhaust emissions 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 11 LESSON 3 POWERTRAIN VCT Operation 15005028 VCT The theory of operation for the 5 4L VCT is similar to the 3 9L VCT used on the Lincoln LS and 2004 Ford F 150 w S 4L The major differences are The 5 4L VCT system controls both intake and exhaust valve timing because the 3 valve setup uses one camshaft for both intake and exhaust valves On the 3 9L the VCT only controls the intake camshafts Parts look different and are serviced differently 5 4L vs 3 9L Part names are different than those used on the 3 9L The VCT can vary cam timing within a range of 60 degrees of crankshaft rotation Defaults to full advance Requires engine oil at preset temperature before VCT will function 3 12 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN The basics of VCT operation are A hydraulic timing mechanism VCT phaser rotates the camshafts in relation to their drive sprockets Provides performance that is precisely tailored to the engine speed and load VCT is electronically controlled PCM duty cycled and hydraulically operated The VCT solenoid moves a spool valve to control the flow of oil through the VCT system Oil flows from the head into th
6. New 6HP26 automatic transmission gear selector Lincoln Navigators are equipped with a new 6HP26 transmission The gear selector allows for manual or automatic selection of first through fourth gear O D disabled and first through sixth O D enabled O D is enabled by moving the gear selector handle to the left while in the D6 D4 gate and is disabled by moving it to the right To accomodate the new gear selector for the 6HP26 transmission the center console has been updated New front seats The 2005 Lincoln Navigator features restyled front seats to improve seating comfort and support 1 8 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 1 OVERVIEW N0017749 2005 Expedition Interior The 2005 Expedition receives minor trim and finish updates as Power fold side view miror switch Limited only The power fold mirrors are operated from a switch that is integral with the power mirror switch In contrast to the power folding mirror switch already available in the Navigator to retract or extend the folding mirrors rotate the mirror adjustment knob to the center position Pressing the switch down one time will fold the mirrors inward Pressing the button again will return the mirrors to their normal position 2005 Expedition Navigator New Model Technician Training 02 SEP 04 1 9 LESSON 1 OVERVIEW Lifting and Jacking Lifting and Jacking Points The front and rea
7. coorta ata ted eo unn 32 d qnn 4 7 APPENDIX imi out st m aaa aaa d du ar btu add iai da aa aa Appendix 1 Appendix Essential Special Service Tools nenea nenea nea Appendix 1 Order ORIN ats NOII O e RE ae E PE PRR ESC oe E atat icta ntt RR un at EDU Appendix 3 Glossary OF Terms sine iip eta ec e e i a s a tai Appendix 5 2005 Expedition Navigator New Model Technician Training 02 SEP 04 i TABLE OF CONTENTS NOTES ii 02 SEP 04 2005 Expedition Navigator New Model Technician Training INTRODUCTION FCSD Technical Training The distance learning course you are about to take is intended to give you new knowledge and information about diagnosing and servicing Ford and Lincoln Mercury vehicles We hope you will apply this knowledge and information to Fix It Right The First Time as part of the effort to satisfy our customer the owners of Ford and Lincoln Mercury products Ground Rules for Successful Completion This course is what we call score based Successful completion of this course requires a passing score of 80 or greater on the Post Test questions Achievement of 80 or greater will result in a PASS in your STARS training history A score of less than 80 results in a FAIL in your STARS training history If you logon and participate in the class but choose NOT to answer any of the questions you will receive an AUDIT in your training history You may return to complete
8. Complete servicing my vehicle in a timely and professional manner Expectation 3 Fix It Right The First Time on Time Both service advisors and technicians are important players when it comes to Expectation 3 Why Customers tell us Fixing It Right The First Time on Time is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced Technician Training It is our goal to help the technician acquire all of the skills and knowledge necessary to Fix It Right The First Time on Time We refer to this as competency Technician s Role Acquire the skills and knowledge for competency in your specialty via STST New Model Self Study Self Study FordStar Broadcasts FordStar Broadcasts Ford Multimedia Training FMT Instructor Led Instructor Led The Benefits The successful implementation of expectations means Satisfied customers Repeat vehicle sales Repeat service sales Recognition that Ford and Lincoln Mercury technicians are the Best in the Business TABLE OF CONTENTS INTRODUCTION Sucia Intro 1 Technical aNg a eels Penile cee eta lalate Chantel iad Au id dea Intro 1 Ground Rules for Successful Completion cccccnnnnncccccnnccconoccccncnnnnnnnnnnncccnnnnnnnnccnnnnnn Intro 1 Eogagihg riesce do A Orn A Intro 2 Keypad OBS abe Intro 3 In Dealership Training Maps rela id id i a a Intro 4 Pl DOSB c o i e
9. The diagnostic tool connects to each network through the Data Link Connector DLC This makes diagnosis and testing of these systems easier by allowing one diagnostic tester to diagnose and control any module on the four networks from one connector The DLC is located under the instrument panel between the steering column and the audio unit 2005 Expedition Navigator New Model Technician Training 02 SEP 04 4 7 LESSON 4 ELECTRICAL Communication Protocols The 2005 Expedition and Navigator feature the following comunication protocols Medium Speed Controller Area Network MS CAN The MS CAN has an unshielded twisted pair cable The MS CAN is used for the Vehicle Dynamics Module VDM the Dual Climate Control Seat Module CCSM the Dual Automatic Temperature Control DATC module the instrument cluster the Parking Aid Module PAM Liftgate Trunk Module LTM and the Vehicle Security Module VSM communications The MS CAN remains operational even with the severing of one of the MS CAN circuits Communication also continues if one of the MS CAN circuits are shorted to ground or voltage or 1f some but not all termination resistors are lost High Speed Controller Area Network HS CAN The HS CAN has an unshielded twisted pair cable The HS CAN is a high speed communications network used for the Anti lock Brake System ABS module the instrument cluster the Transmission Control Module TCM and the Powertrain Control Module PCM c
10. position provides First gear operation only Engine braking for descending steep grades External Controls New floor shift mechanism Lincoln Navigators are equipped with a new 6HP26 transmission This six speed transmission required a new style transmission gear selector This gear selector allows for manual selection of first through fourth gear as well as automatic control of first through fourth O D disabled and first through sixth O D enabled O D is enabled by moving the gear selector handle to the left while in the D6 D4 gate and is disabled by moving it to the right 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 45 LESSON 3 POWERTRAIN Shift Patterns Under certain conditions the transmission automatically downshifts to a lower gear range without moving the range selector lever There are three categories of automatic downshifts coastdown torque demand forced or kickdown shifts Coastdown The coastdown downshift occurs when the vehicle is coasting to a stop Torque Demand The torque demand downshift occurs automatically during part throttle acceleration when the demand for torque is greater than the engine can provide at that gear ratio If applied the transmission will disengage the Torque Converter Clutch TCC to provide added acceleration Kickdown For maximum acceleration the driver can force a downshift by pressing the accelerator pedal to th
11. questions comments or suggestions If you have a concern how would you like it resolved Thanks for your Feedback
12. spare Message Center mmm LF Tire LR Tire Pressure Pressure N0019087 Tire Pressure Monitor TPMS functionality is integrated into Vehicle Security Module VSM located in the right kick panel Communicates with sensor at 315 MHz Blue colored sensor 315 MHz unique for 2005 Expedition and Navigator Sensor Training process is same as previous TPM system with exception of spare tire 2004 sensor Black 433 MHz will NOT work on 2005 Expedition or Navigator Sensor removal and installation process is same as 2004 system Cluster messages for TPMS are different than 2004 A separate warning indicator is used on Expedition models that are not equipped with the optional message center 2 2 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 2 CHASSIS TPMS General Information Temperature fluctuation changes tire inflation pressure 7KPa per 12 degrees Celsius 1 psi per 10 degrees F Article SSM 17496 Date 01 16 2004 TPMS SYSTEM DO NOT USE AFTERMARKET WHEELS SOME 2003 2004 EXPEDITION NAVIGATOR AVIATOR EXPLORER MOUNTAINEER VEHICLES MAY EXHIBIT A TIRE PRESSURE MONITORING SYSTEM TPMS WARNING OR OTHER RELATED CONDITIONS IF AFTERMARKET WHEELS ARE INSTALLED FORD MOTOR COMPANY DOES NOT RECOMMEND USING AFTERMARKET WHEELS ON ANY VEHICLES ESPECIALLY TPMS EQUIPPED VEHICLES ORIGINAL EQUIPMENT OE WHEELS ARE SPECIFICALLY DESIGNED TO ACCOMMODATE TPMS SENSORS AFTERMARKET W
13. the forces generated by the valve and spring movement Reduces engine noise Variable Cam Timing VCT varies cam timing to match performance demands 3 2 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN Charge Motion Control Valves CMCV manage the flow of air into the cylinders Vibration resistant ribbing and reinforcement in the lower engine block help manage and tune sound and vibration The engine block ribbing strengthens the block wall similar to cross reinforcements in a building wall 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 3 LESSON 3 POWERTRAIN T5005051 5 4L Three Valve Head The three valve head has two smaller intake valves and one larger exhaust valve The three valve head includes all of the advantages of the four valve head with fewer parts and less noise A CAUTION Remove the spark plugs before removing the heads The spark plugs are long and can be damaged if left in the head The gap is non adjustable The spark plugs used in the 3 valve head require a special 9 16 inch socket Rotunda Tools among others sells the socket for under 10 00 Order item number SKT4419 from the Rotunda Technician Tool Program RTTP 3 4 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN Air Filter Intake Air Filter Module AFM The intake air distribution and filtering design
14. 4 4 1 LESSON 4 ELECTRICAL Climate Controlled Seats N0017754 Climate Controlled Seats Control Head Item Description Item Description 1 Driver s Side Intensity Level LEDs 3 Passenger s Side Heating Cooling Control Switches 2 Passenger s Side Intensity Level LEDs 4 Driver s Side Heating Cooling Control Switches For 2005 the climate controlled seats utilize one control module located under the passenger side front seat to control both front seats The temperature selection controls are now integrated into the climate control head Both the passenger s side and driver s side seat have separate buttons for heating and cooling The level of heating or cooling is adjusted by pressing and releasing one of these two buttons A series of three LEDs illuminate above each button to indicate its level of intensity For diagnosis and repair information refer to the appropriate section of the Workshop Manual 4 2 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 4 ELECTRICAL Warning Devices ETC Warning New Electronic Throttle Control ETC warning message When an ETC system fault occurs a message is displayed on vehicles equipped with message centers all Navigators and Expeditions with high line instrument clusters On vehicles equipped without message centers Expeditions with the base instrument cluster the ETC warning lamp will illuminate A
15. HEELS MAY NOT BE COMPATIBLE WITH THESE SENSORS AND USE OF NON OE WHEELS MAY RESULT IN ILLUMINATION OF THE TPMS WARNING INDICATOR LOSS OF TIRE PRESSURE TPMS SENSOR DAMAGE OR LOSS OF TPMS FUNCTIONALITY FORD DOES NOT SUPPORT DISABLING THE TPMS SYSTEM IT IS THE INSTALLER S RESPONSIBILITY TO ENSURE AFTERMARKET WHEELS PROVIDE EQUIVALENT FIT AND FUNCTION AS THE OE WHEELS BEING REPLACED INCLUDING TPMS FUNCTIONALITY NOTE This SSM also applies to 2005 model year Expedition and Navigators vehicles 2005 Expedition Navigator New Model Technician Training 02 SEP 04 2 3 LESSON 2 CHASSIS Functionality 2005 Model Year Sensor Wheel Package N0018409 Item Description Item Description 1 Blue 315 Mhz Tire Pressure Sensor 4 sensor system road tires only does not include spare RF based Sensors transmit pressure and unique ID to VSM integrated system Receiver TPM integral to VSM receives information processes information and communicates status to the cluster via MS CAN link TPMS warnings displayed on message center if equipped e All units use NHTSA defined telltale 2 4 2005 Expedition Navigator New Model Technician Training Sensor Description LESSON 2 CHASSIS N0017769 TPMS Sensor Item Description Item Description 1 Transmitter Case 5 Aluminum Valve 2 Air Hole Top 6 Inside Core 3 Potted Surface B
16. Technical Training INTERACTIVE STUDY GUIDE 2005 EXPEDITION NAVIGATOR NEW MODEL TECHNICIAN TRAINING FCS 14000 DL DEALER COMMUNICATIONS NETWORK 2005 EXPEDITION NAVIGATOR NEW MODEL TECHNICIAN TRAINING 02 SEP 04 COURSE CODE 30N29F0 IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe reliable operation of all motor vehicles as well as the personal safety of the individual doing the work This manual provides general directions for accomplishing service and repair work with tested effective techniques Following them will help assure reliability There are numerous variations in procedures techniques tools and parts for servicing vehicles as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly anyone who departs from instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods tools or parts As you read through the procedures you will come across NOTES CAUTIONS and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where care
17. chnicians with the knowledge needed to understand new systems new or updated components and unique diagnostic and service procedures for the 2005 Expedition Navigator AGENDA The information in this course is presented in the following lessons Lesson 1 Overview Lesson 2 Chassis Lesson 3 Powertrain e Lesson 4 Electrical 2005 Expedition Navigator New Model Technician Training 02 SEP 04 Intro 5 INTRODUCTION NOTES Intro 6 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 1 OVERVIEW OBJECTIVES e Identify the new powertrain applications for Expedition and Navigator Identify exterior features Identify interior features Identify lifting and jacking points Identify maintenance check points 2005 Expedition Navigator New Model Technician Training 02 SEP 04 1 1 LESSON 1 OVERVIEW Mechanical and Chassis Features Mechanical and Chassis Features 5 4L 3 Valve Triton Engine w Variable Cam Timing 6HP26 Automatic Transmission Navigator only e 4R75E Automatic Transmission Expedition only 1 2 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 1 OVERVIEW Engine 5 4L N0015678 5 4L 3 Valve Triton Phaser The 2005 Expedition and Navigator are available with one engine New for 2005 the 5 4L 3 valve Triton V8 300 horsepower 5 000 rpm 365 Ib ft of torque 3 750 rpm Variable cam timing Three va
18. corresponding DTC is also stored 2005 Expedition Navigator New Model Technician Training 02 SEP 04 4 3 LESSON 4 ELECTRICAL Instrument Cluster Lighting In 2004 the Navigator had a seperate dimming module that could be serviced seperately For 2005 the dimming control is integrated into the instrument cluster If there is an issue with the dimming system that is isolated to the instrument cluster the entire instrument cluster will require replacement 4 4 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 4 ELECTRICAL Charging System Smart Charge Generator The 2005 Expedition and Navigator are both equipped with a PCM controlled charging system known as Smart Charge On this system the PCM determines the optimal charging voltage setpoint Once the PCM has determined the optimal charging voltage for a given situation the PCM signals the voltage regulator to control generator output This system operates similar to the charging system used on the Crown Victoria Grand Marquis Town Car For diagnosis and repair information refer to the appropriate section of the Workshop Manual 2005 Expedition Navigator New Model Technician Training 02 SEP 04 4 5 LESSON 4 ELECTRICAL Vehicle Security Module For the 2005 Expedition Navigator the Vehicle Security Module VSM strategy has been revised to allow Remote Keyless Entry RKE transmitter data IDs and rolling codes to be retrieved and programmed usi
19. d appear at about the 1 o clock position NOTE The number one piston should have just passed TDC when the crank was turned the normal rotational direction of engine operation 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 23 LESSON 3 POWERTRAIN gt N0016863 Cam Lobe Positioning Item 1 Intake Lobe Description Item Description Exhaust Lobe Pointing Inward The camshaft must be positioned with the 1 or 8 exhaust lobe facing inward to the 3 o clock position If the lobes are not positioned this way the crankshaft will require one full additional rotation to 12 o clock 3 24 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN e PL N0015754 Mark Crankshaft Damper The damper spoke pointing upwards just to the left of the machined notch is the one with the keyway cut in it Chalk mark that spoke for easy viewing 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 25 LESSON 3 POWERTRAIN N0016843 Loosen One Turn Loosen the camshaft phaser bolt one turn Do not remove the bolt A CAUTION DO NOT use an impact wrench when loosening the phaser bolt Impact tools can damage internal phaser components 3 26 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN Intake e Intake Exhaust e 1 N0017772
20. d for a separate module to control the transfer case The PCM utilizes a 190 pin connector New PCM controlled electronically heated PCV port This electrically heated systems uses a heating element enclosed in the PCV tube mounted on the left side of the intake manifold to prevent the valve or tube from freezing On this application the PCV heater uses an inline thermostatic switch When ambient air temperature nears 0 C 32 F this switch completes the Positive Crankcase Ventilation Valve Heater Control PCVHC circuit and turns the heater ON The PCV heater is off when the engine is not running to prevent unnecessary battery drain Dual knock sensors Dual knock sensors mounted in the engine valley provide feedback to the electronic engine control system for controlling spark knock These sensors are accessed by removing the intake manifold assembly 3 36 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN New premium fuel calibration Navigator The aggressive spark and fuel programming requires 91 octane or higher fuel for maximum performance Expedition requires 87 octane fuel for optimal performance NOTE Refer to the Workshop Manual for diagnostic and service procedures for these items 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 37 LESSON 3 POWERTRAIN Fuel Tank and Lines Fuel Tank and Lines New fuel filter
21. e VCT valve body Oil flows through the advance or retard passages as directed by the spool valve Major sensor inputs CMP Oil temperature sensor 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 13 LESSON 3 POWERTRAIN 5 4L 3 Valve Camshaft Position Sensor The VCT system requires a cam position sensor for each camshaft The PCM can then monitor the actual camshaft position relative to the requested position 3 14 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN 75004916 Oil Temperature Sensor The VCT system uses a replaceable oil temperature sensor located on the oil pan Engine oil temperature has a direct effect on VCT operation Cold engine oil has high viscosity and slower flow characteristics The VCT system is disabled at oil temperatures below 7 C 18 F The PCM uses time since start engine oil temperature and engine rpm to calculate VCT solenoid operation Time since start ranges from 60 seconds when cold to 10 seconds when hot Recommended engine oil change intervals must be followed to ensure the integrity of VCT system Oil Capacity 6 6L 7 0 quarts Oil Specification Motorcraft SAE 5W20 Premium Synthetic Blend Motor Oil 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 15 LESSON 3 POWERTRAIN Phaser Components VCT Phaser The VCT compone
22. e body units are combined and installed as a single unit inside the automatic transmission This transmission has the following features six forward speeds a torque converter with an integral converter clutch electronic shift and pressure controls e a single planetary gear set a double planetary gear set two fixed multi disc clutches three multi plate clutches All hydraulic functions are directed by electronic solenoids to control engagement feel 3 40 02 SEP 04 2005 Expedition Navigator New Model Technician Training This transmission has a mechatronic unit valve body which contains shift feel shift scheduling modulated Torque Converter Clutch TCC applications engine braking Turbine Shaft Speed TSS sensor Output Shaft Speed OSS sensor An internal P R N D6 D4 3 2 1 selector shaft position sensor Transmission Fluid Temperature TFT sensor 2005 Expedition Navigator New Model Technician Training 02 SEP 04 LESSON 3 POWERTRAIN 3 41 LESSON 3 POWERTRAIN Operation NIIS v UI mx C N0019086 6HP26 Cutaway Engine power reaches the transmission by a torque converter with an integral converter clutch The six forward gears and one reverse gear are obtained from both single and double planetary sets This automatic transmission is a six speed electronically controlled transmission comprised of a TCM main control valve body unit torqu
23. e converter one solenoid valve and six pressure regulators Gear selection is achieved by the control of automatic transmission fluid flow to operate various internal clutches The TCM operates the electrical components and provides for the control of gear selection shift pressure which increases refinement and torque converter slip In the event of a system fault the TCM also provides for Failure Mode Effect Management FMEM to maintain maximum functional operation of the transmission with a minimum reduction in driver passenger or vehicle safety In the event of a total loss of control or electrical power the basic transmission functions PARK REVERSE NEUTRAL and DRIVE are retained Also 3rd or 5th gear is retained by the hydraulic system The gear retained depends on the gear selected at the time of the failure The 2005 Lincoln Navigator is not equipped with a dedicated O D enable disable switch To disable the O D function the operator must move the gear selector from the D6 sixth gear to the D4 fourth gear position Since this transmission uses a two speed O D fifth and sixth gears upshifts are limited to fourth gear A gear selector position sensor located in the gear selector assembly provides an input to the TCM for control of this function 3 42 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN Identification Tag Identification Tag The identification tag is located on the lef
24. e floor A forced downshift into a lower gear is possible below calibrated speeds Specifications for downshift speeds are subject to variations due to tire size engine and transmission calibration requirements 3 46 02 SEP 04 2005 Expedition Navigator New Model Technician Training Shift Elements LESSON 3 POWERTRAIN N0019090 Shift Elements Item Description Item Description 1 Double Planetary Gearset 6 Overdrive Clutch 2 Forward Clutch 7 Low Reverse Clutch 3 Transmission Case Fixed 8 Single Planetary Gearset 4 Direct Clutch 9 Stator Shaft 5 Intermediate Clutch 10 Turbine Shaft The shift elements are Three rotating multi plate clutches forward direct and overdrive Two fixed multi disc clutches intermediate and overdrive All gear shifts from Ist to 6th or from 6th to 1st are power on overlapping shifts That is during the shift one of the clutches must continue to transmit the drive at lower main pressure until the other clutch is able to accept the input torque 2005 Expedition Navigator New Model Technician Training 3 47 LESSON 3 POWERTRAIN The shift elements are engaged hydraulically The transmission fluid pressure builds up between the cylinder and the piston pressing the clutches together The purpose of these shift elements is to carry out in load shifts with no interruption to traction Multi plate clutches forward direct and overdr
25. eable and is located in the valve body The filter is designed to be self cleaning and should not require any service Oil change interval recommendations are still important 3 20 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN T5005056 Locking Pin The locking pin locks the camshaft in a fully advanced position when the engine is off The pin locks the phaser to the camshaft during startup After startup oil pressure at the VCT assembly will unlock this pin allowing VCT operation to resume Makes it easier to start engine Reduces noise on startup VCT does not control valve timing until the oil temperature reaches 32 F 0 C 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 21 LESSON 3 POWERTRAIN Phaser Camshaft Removal Procedure 15005028 Remove Valve Cover The phaser replacement procedure has been revised for the 5 4L 3V engine This revision allows for the servicing of either the left or right phaser or camshaft without having to remove the engine front cover Remove the left and or right valve cover s 3 22 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN gt Ld TM cr ra 7 N0015753 ER PE ut I F Set Crankshaft Damper Notch to 1 o clock Position Set the crankshaft keyway to 12 o clock The machined notch on the back face of the damper pulley shoul
26. ealth when made airborne by cleaning with compressed air or by dry brushing Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers Dust and dirt should be disposed of in a manner that prevents dust exposure such as sealed bags The bag must be labeled per OSHA instructions and the trash hauler notified as to the contents of the bag If a vacuum bag suitable for asbestos is not available cleaning should be done wet If dust generation is still possible technicians should wear government approved toxic dust purifying respirators OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs Only technicians concerned with performing brake or clutch service should be present in the area Copyright 2004 Ford Motor Company Produced and Coordinated by Technical Support Operations Ford Customer Service Division September 2004 CUSTOMER EXPECTATIONS Customer Expectations Service 1 Make it convenient to have my vehicle 5 Provide me with a clear and thorough serviced at your dealership explanation of the service performed The Service Advisor should 6 Call me within a reasonable amount demonstrate a genuine concern for of time after my service visit to ensure my service needs that I m completely satisfied Fix it right the first time 7 Be responsive to questions or concerns bring to your attention
27. emperature Cylinder Head Temperature CMCV Block Diagram N0017771 The CMCVs are controlled electronically by the PCM The inputs used by the PCM for the CMCV operation are Engine Speed Throttle Position Air Temperature Cylinder Head Temperature The CMCV system does not use a feedback loop The CMCVs open at a predetermined engine speed At higher RPM they do not affect the intake air charge Proper stoichiometric air fuel ratio 14 7 1 is easiest to achieve when the intake air is moving quickly CMCVs close to help the intake air charge move more quickly at low RPM When the opening is narrower the air charge moves more quickly as it enters the combustion chamber Bernoulli s Principle Bernoulli s Principle states that when a given volume of air passes through a smaller passage it will cause the air to speed up 3 10 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN VCT System 75004861 5 4L Variable Cam Timing Solenoid Electrical Connector Conventional camshafts are permanently synchronized with the engine crankshaft to operate the intake and exhaust valves at a specific point in each combustion cycle Variable Cam Timing VCT however allows the valves to operate at variable points in the combustion cycle The VCT system on the 5 4L provides several important benefits Eliminates the need for an EGR system
28. ergy at the clutch pack ncreases transmission service life Improves shift quality Used for trailer towing mode Pressure Modulation This function monitors the hydraulic pressure during a shift This pressure must be matched accurately to the transmission input torque to provide better shift comfort Shift Quality Adapts This function is used to provide a higher quality and consistant shift feel This is acheived by monitoring and adapting shift pressures to account for parts wear and differing driving habits Torque Reduction This function reduces the engine torque output at the time of upshift Trailer Towing This function uses a different shift timing feel and converter operation schedule This schedule reduces the number of gearshifts when towing climbing hills and while driving at higher altitudes 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 59 LESSON 3 POWERTRAIN TCM Monitoring Functions The TCM monitors all transmission inputs and outputs to identify possible transmission failures If a fault is detected the TCM takes the appropriate actions to ensure the transmission enters a safe mode of operations The PCM then sets a DTC and illuminates the Malfunction Indicator Lamp MIL Voltage Supply This function monitors the vehicle s battery life Watchdog Monitoring This feature has two functions Checks for faults in the driver circuits by activating each d
29. has been replaced with New split line welded Intake Air Filter Module IAFM The IAFM is a one piece plastic component that houses the air filter element and Mass Air Flow MAF sensor A CAUTION When removing the air inlet tube from the IAFM be sure to disengage the retaining tab at the top of the tube This can be accomplished by first removing the air filter element and then pushing down on the retaining tab accessed through the air filter door The tube can then be removed without damage The air filter replacement procedure has changed Air filter tray slides out of the intake assembly Remove the air filter from the tray for replacement A Motorcraft brand air filter is strongly recommended because of better sealing characteristics NOTE During installation ensure the filter tray is fully seated Engine noise may leak into the underhood compartment and introduce unnecessary NVH 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 5 LESSON 3 POWERTRAIN d f A SS 75004991 Mass Air Flow MAF Sensor The compact Mass Air Flow MAF sensor is located on the IAFM This sensor combines the Intake Air Temperature IAT and the MAF sensor 3 6 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN Electronic Throttle Control ETC Oe 15004988 ETC Throttle Body The 5 4L 3V engine used in both the Exped
30. if dropped or mishandled 3 18 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN 75005027 VCT Solenoid Removal The VCT solenoid is serviced separately from the VCT valve body No special tools are needed to remove the solenoid The retaining bolt is captured in the mounting tab 1 Disconnect the solenoid electrical connection 2 Remove the valve cover grommet 3 Remove the hold down bolt A Remove the solenoid A CAUTION Do not drop the solenoid screw into the front cover If the screw drops into the front cover the front cover must be removed to retrieve the screw Do not use power tools to remove the screw A CAUTION Use care to prevent contamination from falling in the valve body spool bore Thoroughly clean around cam cover and solenoid seal before removing the seal and solenoid 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 19 LESSON 3 POWERTRAIN 75004883 VCT Valve Body Oil Passages Item Description Item Description 1 Solenoid filter 5 Oil passage back into head 2 Oil passage to advance side of VCT 6 Oil metering orifice 3 Oil passage to retard side of VCT 7 Oil passage from head 4 Oil passage to chain tensioner The valve body and solenoid work together to route oil to the vanes in the camshaft phaser to operate the VCT system NOTE The solenoid filter is not removable or servic
31. in the Fall of 2005 These modules are the Global Driver s Seat Module the Dual Climate Control Seat Module the Vehicle Security Module and the Instrument Cluster Delivery methods for module updates will be the same as those used currently CDs and FORDSTAR 4 8 02 SEP 04 2005 Expedition Navigator New Model Technician Training APPENDIX ESSENTIAL SPECIAL SERVICE TOOLS ESSENTIAL SPECIAL SERVICE TOOLS 2005 Expedition Navigator New Model Technician Training 02 SEP 04 Appendix 1 APPENDIX ESSENTIAL SPECIAL SERVICE TOOLS NOTES Appendix 2 02 SEP 04 2005 Expedition Navigator New Model Technician Training APPENDIX ESSENTIAL SPECIAL SERVICE TOOLS 2005 Expedition Navigator New Model Technician Training 02 SEP 04 Appendix 3 APPENDIX ESSENTIAL SPECIAL SERVICE TOOLS Appendix 4 02 SEP 04 2005 Expedition Navigator New Model Technician Training APPENDIX GLOSSARY OF TERMS GLOSSARY OF TERMS 2005 Expedition Navigator New Model Technician Training 02 SEP 04 Appendix 5 APPENDIX GLOSSARY OF TERMS NOTES Appendix 6 02 SEP 04 2005 Expedition Navigator New Model Technician Training Technical Training Questions Comments Suggestions FAX Form Please use this form to contact us regarding Technical Training Courses on FORDSTAR Fax this form to the Technical Training FAX Line at 313 317 7194 Dealership Your Name Phone Number Course Dealer P amp A Code Date You Took Course Dealer FAX Phone Your I D Number Please write your
32. is attached to the case of the transmission and is accessible through the pan filter assembly A CAUTION When removing the TCM main control valve body assembly it is important to first remove the connection adaptor This is accomplished by releasing the white locking mechanism and pulling out on the adaptor Failure to remove the adaptor before removing the TCM main control valve body assembly will result in damage to the adaptor or TCM main control valve body assembly 3 52 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN Transmission Electronic System The TCM receives input signals from certain transmission related sensors and switches The TCM uses these signals to control the following operations Shift timing Line pressure shift feel Torque converter clutch To accomplish this the TCM uses six pressure control solenoids and one shift solenoid to control transmission operation Five pressure regulators and one solenoid valve are used to control direct transmission fluid flow to select internal clutches and control the fluid pressure at the clutch A separate pressure regulator is used exclusively for torque converter clutch control The following provides a brief description of each of the sensors and actuators used to control transmission operation 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 53 LESSON 3 POWERTRAIN Transmission Control Module TCM
33. ition Navigator New Model Technician Training 02 SEP 04 3 61 LESSON 3 POWERTRAIN Transmission Cooling Transmission Cooling New quick connect transmission oil cooler lines Quick connect fittings are used at the transmission line to radiator cooler connections Use ESST 307 441 Disconnect Tool Transmission Cooler Line to disconnect lines for service Refer to the Workshop Manual for diagnostic and service procedures 3 62 02 SEP 04 2005 Expedition Navigator New Model Technician Training 6HP26 Transmission Special Service Tools Item 307 552 307 553 307 554 307 555 307 556 307 557 307 558 307 559 307 560 307 562 2005 Expedition Navigator New Model Technician Training 02 SEP 04 LESSON 3 POWERTRAIN Description Direct Clutch Service Fixture Front Pump Removal Tool D Clutch Stack Gauge Clutch Pack End Play Gauge Fluid Pump 4x2 Rear Seal Installer Case Bearing Installer Case Second Bearing Installer Shifter Seal Installer 4x4 Rear Seal Installer Case Bearing Remover 3 63 LESSON 3 POWERTRAIN 3 64 NOTES 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 4 ELECTRICAL OBJECTIVES e Identify ETC warning features Identify climate control features Identify charging system features e Identify Vehicle Security Module VSM features Identify module communication features 2005 Expedition Navigator New Model Technician Training 02 SEP 0
34. ition and Navigator utilizes Electronic Throttle Control ETC This system functions and is serviced similarly to the systems used on the Thunderbird and LS Warning indications are via an instrument cluster mounted message center or warning light This is covered in greater detail in Lesson 4 Refer to the Work Shop Manual for additional information on ETC service and diagnostics 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 7 LESSON 3 POWERTRAIN N0017752 Charge Motion Control Valves CMCV The Charge Motion Control Valves CMCV are electronically controlled metal flaps at the end of each intake runner eight in total four per bank on one rod operated together e CMCVs work to speed up the intake air charge and induce a tumble effect into the combustion chamber at low engine speeds and loads Causes a thorough mix of the air fuel charge Results in a quick efficient burn which helps reduce emissions Close at low engine speeds and light loads Helps manage noise vibration and harshness 3 8 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN 15005409 CMCV Motor The CMCVs use one electronically controlled motor to operate the CMCVs for both sides of the intake manifold 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 9 LESSON 3 POWERTRAIN Engine Speed Throttle Position Air T
35. ive supply power from the engine to the planetary gear train Multi disc brakes intermediate and low reverse press against the transmission housing in order to achieve a torque reaction effect 3 48 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN Multi Plate Clutch gt N0015694 Multi Plate Clutch Item Description Item Description 1 Clutch Pack Cluster 6 Turbine Shaft 2 Piston 7 Lubricating Oil Passage 3 Cylinder 8 Cup Spring 4 Ring Gear Planetary Gearset 1 9 Baffle Plate 5 Main Pressure Supply to Clutch 10 Inner Plate Carrier Multi plate clutches are used exclusively throughout the 6HP26 transmission No bands are used 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 49 LESSON 3 POWERTRAIN Fluid Pan Gasket and Filter N0015696 Fluid Pan Gasket and Filter The transmission fluid pan gasket and filter is a one piece assembly All transmission fluid is drawn from the transmission fluid pan by the fluid pump and passes through the filter To drain and fill the 6HP26 transmission perform the following steps Drain With the vehicle in NEUTRAL position it on a hoist 1 Remove the fluid pan drain plug and allow the fluid to drain 2 Remove the pan assembly and replace the entire unit Fill 1 Install the fluid pan drain plug and tighten to 8 Nm 71 Ib in 2 Remove the fluid fill p
36. lessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a vehicle To prevent serious burns avoid contact with hot metal parts such as the radiator exhaust manifold tail pipe Always wear safety glasses for eye protection Use safety stands whenever a procedure requires you to be under the vehicle Be sure that the ignition switch is always in the OFF position unless otherwise required by the procedure Set the parking brake when working on the vehicle If you have an automatic transmission set it in PARK unless instructed otherwise for a specific service operation If you have a manual transmission it should be in RE VERSE engine OFF or NEUTRAL engine ON unless instructed otherwise for a specific service operation Operate the engine only in a well ventilated area to avoid the danger of carbon monoxide Keep yourself and your clothing away from moving parts when the engine is running especially the fan and belts catalytic converter and muffler Do not smoke while working on the vehicle To avoid injury always remove rings watches loose hanging jewelry and loose clothing before beginning to work on a vehicle Tie long hair securely behind your head Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temperatures even though the ignition is in
37. lug located on the RH rear side of the case near the transmission electrical connector 3 Fill the transmission with approximentally 4 7 liters 5 quarts of new Mercon SP automatic transmission fluid through the fluid fill hole Stop when the fluid runs out of the bottom of the hole 4 Install the fluid fill plug located on the RH rear side of the case near the transmission electrical connector 3 50 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN 5 Start the engine Move the transmission range selector lever through all the gear ranges checking for engagements 6 With the engine idling 600 750 rpm in PARK and the transmission temperature at 30 C 50 C 86 F 122 F check and adjust the transmission fluid level 7 If more fluid is needed remove the fluid fill plug on the side of the case and fill until the fluid runs out of the bottom of the hole 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 51 LESSON 3 POWERTRAIN Transmission Control Module TCM and Main Control Valve Body N0015697 Transmission Control Module TCM and Main Control Valve Body The Main Control assembly 7A100 referred to as the mechatronic unit is made up of the following components the TCM processor seven control solenoids and a typical main control assembly The main control component houses valves and springs within the two halves upper and lower The mechatronic unit
38. lves per cylinder Electronic Throttle Control ETC Rather than focusing on a single item to gain improvements in power Ford used an approach that included advancements on multiple fronts These improvements contribute to overall power with reduced NVH at low engine speeds Some of these changes are outlined below he three valve design achieves same benefits as a four valve design Three valve design balances the forces generated by the valve and spring movement Reduces engine noise 2005 Expedition Navigator New Model Technician Training 02 SEP 04 1 3 LESSON 1 OVERVIEW Variable Cam Timing VCT varies cam timing to match performance demands Charge Motion Control Valves CMCV manage the flow of air into the cylinders Vibration resistant ribbing and reinforcement in the lower engine block help manage and tune sound and vibration The engine block ribbing strengthens the block wall similar to cross reinforcements in a building wall 1 4 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 1 OVERVIEW Automatic Transmission N0015685 5685 oO 6HP26 Transmission The 2005 Expedition will use the 4R75E automatic transmission like the 2004 and 2005 F 150 while the Navigator uses the all new 6HP26 automatic The 6HP26 6 speed transmission uses total electronic control for all functions The Transmission Control Module TCM and the main control valve body units are combi
39. missing or are incorrectly trained 3 No MS CAN communication Solution 1 Refer to pin point test C described in the Workshop Manual 2 Train the TPMS sensors If training cannot be completed you may have the wrong sensors MY 04 Black 433 MHz sensors or you re missing all sensors 3 Refer to Workshop Manual for communication issues NOTE Always refer to the Workshop Manual for complete diagnostic information 2 10 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 2 CHASSIS Driveshaft Driveshaft Navigator 4x2 models use a unique 2 piece driveshaft Staked U Joint Service The original u joints are staked in place There is no retaining clip The factory u joints require the use of a special cutting tool to remove the stakes prior to the removal of the u joint cups After appropriately mounting the driveshaft in a vise the cutting tool which is part of the u joint replacement kit is rotated by using a ratchet handle to remove the stakes Once the stakes are removed remove and replace the u joints in the conventional manner Refer the appropriate section of the Workshop Manual for further details New torsional dampener A torsional dampener effectively isolates vibrations produced within the driveline from the rest of the vehicle 2005 Expedition Navigator New Model Technician Training 02 SEP 04 2 11 LESSON 2 CHASSIS Front Drive Axle Differential Fron
40. ned and installed as a single unit inside the automatic transmission Hydraulic functions are directed by electronic solenoids to control engagement feel shift feel shift scheduling modulated Torque Converter Clutch TCC applications engine braking 2005 Expedition Navigator New Model Technician Training 02 SEP 04 1 5 LESSON 1 OVERVIEW Exterior Features N0015734 2005 Navigator Exterior New body side cladding Bold new body side cladding is added to the 2005 Lincoln Navigator The cladding is painted body color and enhances as well as protects the exterior appearance e New front fascia An agressive front fascia is standard on the Lincoln Navigator and comes with integral fog lamps and front spoiler High Intensity Discharge HID headlamps are optional on all models 1 6 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 1 OVERVIEW 2005 Expedition Exterior New badging for Limited and FX4 mid 4th quarter availability Expedition for 2003 comes with new badging when equipped with the Limited and FX4 packages New power fold side view mirrors Expedition Limited for 2005 comes with new power fold side view mirrors The mirrors are controlled by a switch that is integral with the power mirror switch 2005 Expedition Navigator New Model Technician Training 02 SEP 04 1 7 LESSON 1 OVERVIEW Interior Features 2005 Navigator Interior
41. ng diagnostic tools It is no longer necessary to reprogram the remote transmitters when a VSM is replaced When a VSM is replaced using the PMI procedure remote transmitter data is now also transferred to the new module The Workshop Manual has been updated for 2005 with this procedure change NOTE When programming the VSM using as built data it will still be necessary to program the remote transmitters to the VSM 4 6 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 4 ELECTRICAL i Module Communication Network Description of Change Parking Aid Navigator changes from UBP to MS CAN X Expedition utilizes ISO 9141 BSM w TPMS Changes from UBP to MS CAN F Changes from UBP SCP to MS CAN HS CAN Cluster gateway Dual Climate Control Seat Module DCSM Changes from UBP to MS CAN x Global Driver Seat Changes from UBP to MS CAN x Module GDSM LNS Navigation ECU Maintain SCP for diagnostics only ia Power Liftgate PLGM Changes from UBP to MS CAN 4 Wheel Air Suspension 4WAS or Vehicle Changes from UBP to MS CAN x x Dynamics Module VDM Antilock Brake System h f P to HS CAN ABS Module Changes from UBP to HS C Dual Automatic Temperature Control Changes from UBP to MS CAN X X DATC Powertrain Control Module PCM Changes from SCP to HS CAN X uonipedx3 DT eb eR E etm X X X O v X X Ls e x e wos N0019089 Module Communication Network
42. nsor is a temperature dependent resister thermister The TCM uses the TFT signal to determine whether a cold start shift schedule is necessary The cold start shift schedule allows quicker shifts when the transmission fluid temperature is cold The TCM also inhibits torque converter clutch operation at low transmission fluid temperatures The TCM can diagnose electrical errors associated with the TSS and OSS sensors while the vehicle is stationary as well as moving Plausability monitoring is carried out on the sensor output when the engine is running 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 57 LESSON 3 POWERTRAIN Transmission Range Position Sensor N0015704 Transmission Range Position Sensor The TCM uses the position of this switch housed on the TCM and main control valve body to determine the selected gear range from the range selector lever The sensor completes the start circuit in PARK and NEUTRAL and the back up lamp circuit in REVERSE The sensor also opens closes a set of switches that are monitored by the TCM to determine the position of the manual lever P R N D6 D4 3 2 1 3 58 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN Transmission Operational Strategies Adaptive shift strategy is comprised of the following functions Shift Energy Management Reduces or increases engine output torque during shifting Reduces excessive en
43. nts include Camshaft phaser sprockets Right and left camshaft phaser sprocket assembly bolt and washer VCT valve bodies housing VCT solenoids Right and left camshafts NOTE The phaser phaser sprocket vanes and the return spring are serviced as an assembly 3 16 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN T5005055 Phaser Oil Vanes The oil vanes create oil cavities for valve directed oil to rotate the camshaft in relation to the crankshaft Oil pushes on one side of the vanes to rotate the cam in one direction to advance timing Oil pushes on the other side of the vane to rotate the cam in the other direction to retard timing 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 17 LESSON 3 POWERTRAIN 75004995 VCT Phaser Disassembled The VCT phaser varies camshaft timing in response to oil pressure exerted on either side of the vanes A CAUTION Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit A CAUTION Always install a new bolt and washer whenever the VCT phasers are loosened The base part number is 6279 The same part number is used for both sides NOTE These bolts are one time torque only and are available separately or as part of the phaser replacement kit A CAUTION Handle the cam and phaser carefully Damage will occur
44. odel Technician Training 02 SEP 04 2 9 LESSON 2 CHASSIS Possible Failure Modes and Root Causes TPMS indicator light stays ON continuously Message center if equipped Displays Low Tire Pressure Causes 1 Air pressure is low or not set to required placard pressure 2 Spare tire currently in use Solution 1 Check tire pressure with digital gauge If issue still persists then retrieve DTC and follow pin point test F2 described in service manual 2 Repair original tire and install road wheel tire TPMS indicator light Flashes for approx 20 sec At key ON position Message center if equipped Displays Tire Pressure Sensor Fault Causes 1 TPMS sensors failed missing sensor after market wheels or sensor incorrectly trained 2 Vehicle may have sat stationary for 10 or more days This will not always happen but in some cases if vehicle is parked and is stationary for 10 or more days you may see this event Solution 1 Train TPMS sensors If issue still persists then retrieve DTC and follow pin point test C described in Workshop Manual 2 Drive vehicle for 5 minutes and cycle the ignition key to the RUN position Verify the fault is gone and clear the DTC TPMS indicator light Flashes for approx 20 sec At key ON position Message center if equipped Displays Tire Pressure Monitor Fault Causes 1 Module failure 2 All four TPMS sensors have failed are
45. ommunication The HS CAN remains operational even with the severing of one of the HS CAN circuits Communication also continues if one of the HS CAN circuits are shorted to ground or voltage or if some but not all termination resistors are lost e 18509141 Network The ISO 9141 communications network is a single circuit communications network The ISO 9141 communications network does not permit intermodule communication When the diagnostic tool communicates to modules on the ISO 9141 communications network the diagnostic tool must request all information or initiate module commands The ISO 9141 communications network does not function if the circuit is shorted to ground or battery voltage Also if one of the modules on the ISO 9141 communications network loses power or shorts internally communications to that module will fail Standard Corporate Protocol SCP Network The SCP communications network Navigator with navigation system only remains operational even if one of the SCP communications network circuits are severed Communications also continue if one of the SCP communications network circuits are shorted to ground or voltage or if some but not all termination resistors are lost The SCP communications network allows inter module communication Module Programability Many of the Body Modules on the 2005 Expedition Navigator are flash capable at the dealership level Body module flash capability will be coming to dealerships
46. or New Model Technician Training 02 SEP 04 3 29 LESSON 3 POWERTRAIN 5 N0016845 Loosen 1 Camshaft Bearing Cap Bolts Mark the cam caps for proper reinstallation NOTE The camshaft bearing caps must be installed in their original locations Record camshaft bearing cap locations Loosen the camshaft bearing caps Start with the 1 cap because it contains a thrust surface groove If the cam were to be moved in some fashion with this cap intact the cap could be damaged or broken Remove the remaining cap bolts according to Workshop Manual procedures 3 30 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN N0016846 Remove the Phaser Bolt The remaining followers will be loose on the lifters Be sure to keep them in place so that the camshaft can be reinstalled Remove the CMP sensor Fully withdraw the camshaft sprocket phaser bolt by hand 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 31 LESSON 3 POWERTRAIN N0016847 Remove the Phaser Using extreme care withdraw the phaser from the nose of the camshaft It may be necessary to slightly tip up the cam from the rear to allow chain disengagement A CAUTION Do not let the camshaft set in the cylinder head unattended The cam may fall out 3 32 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN Cam and Phaser Reassembly
47. ottom 7 Nut 4 Grommet 8 Cap 315 MHz Blue Manchester Encoded AM Pressure Sampling Transmission Stationary 15 minute sample 1 hour transmission Rolling 30 second sample 1 minute transmission Motion switch sampling rate 10 second Full Scale Pressure Range 0 64 psi e 24 Bit Electronic ID Code 2005 Expedition Navigator New Model Technician Training 2 5 LESSON 2 CHASSIS Module Description TPM System integrated into Vehicle Security Module VSM Module designed to Receive tire pressure and sensor information 315MHz transmissions from sensors Process input information determine correct status and associate sensors with module learn Communicate status to message center via MS CAN Output to horn relay self test and manual learn mode 2 6 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 2 CHASSIS Cluster Messages The following are messages that can be displayed on the message center if equipped on Expedition models standard on Navigator Customer Normal Message LOW TIRE PRESSURE Customer System Check TIRE PRESSURE SYSTEM ACTIVE Service TIRE TRAINING COMPLETED TRAIN RF TIRE TRAIN LF TIRE TRAIN RR TIRE TRAIN LR TIRE TIRES NOT TRAINED REPEAT System Faults TIRE PRESSURE MONITOR FAULT TIRE PRESSURE SENSOR FAULT The following are operating condi
48. r lifting and jacking locations are as indicated 1 10 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 1 OVERVIEW Maintenance Check Points N0017757 Y Maintenance Check Points Navigator Shown Item Description Item Description 1 Cabin Air Filter 6 Engine Coolant Engine Air Filter 7 Engine Oil Fill Power Steering Fluid 8 Windshield Washer Solvent 9 Engine Oil Dipstick Battery Brake Fluid Un BR wld All maintenance point locations are carry over from 2004 with the exception of the transmission fluid on Lincoln Navigator and air filter element on both Expedition has a conventional transmission dipstick located near the right rear corner of the engine Refer to the Workshop Manual for the proper maintenance schedule and fluid specifications 2005 Expedition Navigator New Model Technician Training 02 SEP 04 1 11 LESSON 1 OVERVIEW 1 12 NOTES 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 2 CHASSIS OBJECTIVES e Identify changes to the TPMS Identify new suspension system features e Identify new drive axle differential driveline features 2005 Expedition Navigator New Model Technician Training 02 SEP 04 2 1 LESSON 2 CHASSIS Wheels and Tires RF Tire RR Tire Pressure Pressure Instrument Q D Warning Indicator VSM in right kick panel No sensor in
49. river Checks to see if the safety circuit is functioning correctly TCM Temperature If the TCM temperature raises above a predetermined level the TCM shuts down Prior to shutting down the TCM logs a fault code during the shut down The transmission enters a mechanical limp home mode Pressure Regulator Solenoid Each pressure regulator and solenoid is monitored for open and short circuits The TCM also checks that the current being delivered to each solenoid valve or pressure regulator is within limits Torque Converter Control The TCM checks and verifies that the torque converter has been engaged correctly If the torque converter has not engaged correctly the TCM will carry out the fail safe action of opening the converter clutch 3 60 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN Monitoring The Substrate Temperature Sensor N0015705 Substrate Temperature Sensor The TCM controls a number of high power solenoids and is surrounded by automatic transmission fluid As a result the TCM can get very hot If the temperature of the hardware rises above a predetermined temperature the TCM shuts down Prior to shutting down the TCM logs a fault code and illuminates the MIL Following the shut down the transmission enters a mechanical limp home mode Monitoring of the substrate temperature is carried out by a temperature dependent resistor mounted in the processor 2005 Exped
50. rt te RUM MEDI MM M Intro 5 MM M M mee Intro 5 LESSON 1 OVERVIEW ice cce exuo ri fa nai iia 1 1 ODIBEHVOS ea eic dA uM LIU Cc ADI A AUD A Mi 1 1 Mechanical and Chassis Features intacta 1 2 Exterior Feli a a eat eta E N 1 6 Interior Feat res nl ns 1 8 latio feck Jacking rosna tara dau a 1 10 Maintenance Check Points 20 ios 1 11 LESSON 2 CHASSIS iia olla idad 2 1 OD SCI Si ads 2 1 Wh sis a d les es actam Dern reno Dd 2 2 Dive M 2 11 Front Drive Axie Differeritlal octet ace datata tat i ua i a bee ciet eed eU pe 2 12 LESSON 3 POWERTRAIN 5 vi aie biata iu au aa Buca tanar oa du C aia oap Ee DO ba 3 1 COB SCUVES M 3 1 Ende 5 41 ostio Gee E bate as 3 2 Electronic Engine COMO Sisi bo rin rote pce p e teo pcd adire ead agas 3 36 Fuel Tank ANOIMAS s prece Mee Bate 3 38 Engine Special Service Tools nenea eee anna en anaaee 3 39 Automatic TES SDHISSIOEU s o oett tie la ia LA atleti ote 3 40 TASAS COOUNG Ces tater prlde iata ai dai A tati aia 3 62 6HP26 Transmission Special Service Tools m nene eee nenea ana 3 63 LESSON 4 ELECTRICAL e tii ag a ii Ci i t pa iat air iai ii 4 1 O Loa e ttt asa 4 1 Climate Controlled SCAG iei dea 4 2 A AE 4 3 Instrument Cluster Lig IMG cb 4 4 Charging A aad et ees cd at ana eb tM anid oi on vi wate ete Staten dies 4 5 Vehicle Security Module ca iaz iarna inc ibas 4 6 Module Communication NOetWoFK
51. so checks that the current being delivered to each solenoid or pressure regulator is within valid limits If current exceeds predetermined limits the TCM sets a DTC illuminates the MIL and enters the limp home mode 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 55 LESSON 3 POWERTRAIN Controller Area Network CAN Interface N0019085 Controller Area Network CAN Interface BUSSED INPUTS OUTPUTS For the TCM to carry out shift point and shift quality management a number of external signals are required For shift point management the TCM requires Output Shaft Speed OSS sensor Accelerator Pedal Position APP sensor Brake Pedal Position BPP switch and Transmission Range TR sensor The High Speed Controller Area Network HS CAN bus is used to share information between control modules 3 56 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN Sensors Integrated With TCM N0019088 Sensors Integrated With TCM Item Description Item Description 1 Output Shaft Speed OSS Sensor 3 Turbine Shaft Speed TSS Sensor 2 Transmission Fluid Temperature TFT Sensor Several sensors are located on the TCM and main control valve body unit The Turbine Shaft Speed TSS sensor is a Hall effect type sensor The Output Shaft Speed OSS sensor is a Hall effect type sensor The Transmission Fluid Temperature TFT se
52. spond If you change your mind about asking the question simply press the CALL key again As long as the instructor has not accepted your call this takes you out of the call queue WAIT and SPEAK Lights The red WAIT light illuminates when your call is received and placed in the call queue When the instructor calls on you the green SPEAK light illuminates and your microphone is activated The microphone is the gray dot between the SPEAK and WAIT lights Speak in a normal tone of voice from a normal sitting position The instructor will hear you as will all the other students wherever they are located FLAG Key Use the FLAG key when requested by the instructor The FLAG key is usually used to alert the instructor that you have completed tests or exercises 2005 Expedition Navigator New Model Technician Training 02 SEP 04 Intro 3 INTRODUCTION IN DEALERSHIP TRAINING MAP Which Service Identify Department Personnel Dealership Should Attend the 2005 Training E Expedition Navigator Requirements New Model Technician Training Service Advisors Service Technicians and Managers View 2005 Navigator Expedition New Model Technician Training FORDSTAR Course 30N29F0 FIRTFTOT Capable Dealership Chassis Powertrain Electrical Body Intro 4 02 SEP 04 2005 Expedition Navigator New Model Technician Training INTRODUCTION PURPOSE The purpose of this FORDSTAR course is to provide Ford and Lincoln Mercury service te
53. t Drive Axle Differential New companion flange The design of the front axle companion flange is unique to the 2005 Expedition and Navigator When servicing be sure to obtain the proper parts for your specific application 2 12 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN OBJECTIVES e Identify new 5 4L 3 valve engine features Explain the operation of the VCT system Explain the revised procedure for camshaft or phaser assembly replacement Identify 6HP26 automatic transmission features Explain the basic functions of the 6HP26 transmission controls Explain the basic shift control strategies of the 6HP26 transmission 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 1 LESSON 3 POWERTRAIN Engine 5 4L N0015678 5 4L 3 Valve Triton Phaser The 2005 Expedition and Navigator are available with one engine New for 2005 the 5 4L 3 valve Triton V8 300 horsepower 5 000 rpm 365 lb ft of torque 3 750 rpm Variable cam timing Three valves per cylinder Rather than focusing on a single item to gain improvements in power Ford used an approach that included advancements on multiple fronts These improvements contribute to overall power with reduced NVH at low engine speeds Some of these changes are outlined below The three valve design achieves same benefits as a four valve design Three valve design balances
54. t side of the case just rearward of the manual control lever 2005 Expedition Navigator New Model Technician Training 02 SEP 04 3 43 LESSON 3 POWERTRAIN Range Selection N0015688 Shifter Pattern The transmission has eight range positions P R N D6 D4 3 2 and 1 In the Park position There is no power flow through the transmission The parking pawl locks the output shaft to the case The engine can be started The ignition key can be removed In the Reverse position The vehicle can be operated in a rearward direction at a reduced gear ratio The backup lamps are illuminated In the Neutral position There is no power flow through the transmission The output shaft is not held and is free to turn The engine can be started 3 44 02 SEP 04 2005 Expedition Navigator New Model Technician Training LESSON 3 POWERTRAIN The D6 position is the normal position for most driving conditions It provides Automatic shifts 1 6 and 6 1 Apply and release of the torque converter clutch Maximum fuel economy during normal operation Engine braking in sixth gear The D4 position provides Automatic shifts 1 4 and 4 1 Apply and release of the torque converter clutch Engine braking in fourth gear The Manual 3 position provides Manual 3rd gear only Engine braking in third gear The Manual 2 position provides Manual 2nd gear only Engine braking in second gear The Manual 1
55. the OFF position Therefore care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and or service department operations These recommendations and suggestions do not supersede or override the provisions of the Warranty and Policy Manual and in any cases where there may be a conflict the provisions of the Warranty and Policy Manual shall govern The descriptions testing procedures and specifications in this handbook were in effect at the time the handbook was approved for printing Ford Motor Company reserves the right to discontinue models at any time or change specifications design or testing procedures without notice and without incurring obligation Any reference to brand names in this manual is intended merely as an example of the types of tools lubricants materials etc recommended for use Equivalents if available may be used The right is reserved to make changes at any time without notice WARNING MANY BRAKE LININGS CONTAIN ASBESTOS FIBERS WHEN WORKING ON BRAKE COMPONENTS AVOID BREATHING THE DUST BREATHING THE ASBESTOS DUST CAN CAUSE ASBESTOSIS AND CANCER Breathing asbestos dust is harmful to your health Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your h
56. the test in a future class session if desired Completion of the test will replace the AUDIT in your STARS training history 2005 Expedition Navigator New Model Technician Training 02 SEP 04 Intro 1 INTRODUCTION LOGGING ON AA 75002413 Your response keypad transmits data and voice between you and the host site via telephone lines and satellite It is gt gt your lifeline connecting you to the instructor as well as to other participants Using the keypad you can become fully involved in the seminar asking questions and contributing relevant comments To log on at the beginning of the broadcast session 1 Enter your Social Security number in response to the keypad prompt If you press an incorrect key press CLEAR and re enter the numbers 2 Press ENTER 3 The system validates your ID number by displaying your name on your keypad If your name does not appear on the keypad re enter your ID number 4 If you cannot successfully log on contact the FORDSTAR Help Desk USA Dealers call 1 800 790 HELP 4357 Canadian Dealers call 1 800 467 8925 Intro 2 02 SEP 04 2005 Expedition Navigator New Model Technician Training INTRODUCTION KEYPAD OPERATION CALL Key Press the CALL key if you have a question or comment This places you in the call queue The system indicates your name and location to the instructor It takes approximately 60 seconds for the instructor to re
57. tions for the TPM warning indicator Low tire pressure Warning indicator is ON SOLID Sensor Monitor fault The warning indicator flashes for approximately 20 seconds after the event occurs and after every key cycle until condition is corrected 2005 Expedition Navigator New Model Technician Training 02 SEP 04 2 7 LESSON 2 CHASSIS DTCs DTC B1342 B2477 B2868 B2869 B2870 B2871 B2872 B1217 C2780 2 8 02 SEP 04 Description ECU Defective Module Configuration Failure Left Front Sensor Fault Right Front Sensor Fault Right Rear Sensor Fault Left Rear Sensor Fault Tire Sensor Fault Horn Relay Circuit Failure ECU in Manufacturing Mode 2005 Expedition Navigator New Model Technician Training LESSON 2 CHASSIS TPMS PIDs NGS Name WDS Name Description LF_ID LF_ID_VSM LEFT FRONT TIRE SENSOR ID RF_ID RF_ID_VSM RIGHT FRONT TIRE SENSOR ID RR_ID RR_ID_VSM RIGHT REAR TIRE SENSOR ID LR_ID LR_ID_VSM LEFT REAR TIRE SENSOR ID LF_PRES LF_PSI_VSM BP COMPENSATED PRESSURE CALCULATED BY MODULE BARO COMP VALUE RF_PRES RF_PSI_VSM BP COMPENSATED PRESSURE CALCULATED BY MODULE BARO COMP VALUE RR_PRES RRO_PSI_VSM BP COMPENSATED PRESSURE CALCULATED BY MODULE BARO COMP VALUE LR_PRES LRO_PSI_VSM BP COMPENSATED PRESSURE CALCULATED BY MODULE BARO COMP VALUE TPM_TT N A TIRE PRESSURE TELL TALE STATUS VSM commanding telltale status to cluster 2005 Expedition Navigator New M
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