Ford FCSD TECHNICAL TRAINING FCS-14000-DL Manuel de l'utilisateur

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Page 1 - Technical Training


Page 2

INTRODUCTIONIN-DEALERSHIP TRAINING MAP2005 Expedition/Navigator New Model Technician Training02-SEP-04Intro-4


LESSON 3: POWERTRAINNOTES2005 Expedition/Navigator New Model Technician Training02-SEP-043-64


LESSON 4: ELECTRICALOBJECTIVES•Identify ETC warning features.•Identify climate control features.•Identify charging system features.•Identify Vehicle S


LESSON 4: ELECTRICALClimate Controlled Seats Climate Controlled Seats Control HeadItem Description Item Description1 Driver’s Side Intensity Level LED

Page 6

LESSON 4: ELECTRICALWarning Devices ETC Warning•New Electronic Throttle Control (ETC) warning message.•When an ETC system fault occurs, a message is d

Page 7

LESSON 4: ELECTRICALInstrument Cluster Lighting •In 2004 the Navigator had a seperate dimming module that could be serviced seperately. For 2005, thed

Page 8

LESSON 4: ELECTRICALCharging System Smart Charge Generator•The 2005 Expedition and Navigator are both equipped with a PCM-controlled charging system k

Page 9 - FLAG Key

LESSON 4: ELECTRICALVehicle Security Module For the 2005 Expedition/Navigator, the Vehicle Security Module (VSM) strategy has been revised to allowRem


LESSON 4: ELECTRICALModule Communication Network Module Communication NetworkThe diagnostic tool connects to each network through the Data Link Connec

Page 11

LESSON 4: ELECTRICALCommunication Protocols The 2005 Expedition and Navigator feature the following comunication protocols: •Medium Speed Controller A

Page 12

APPENDIX: ESSENTIAL SPECIAL SERVICE TOOLSESSENTIAL SPECIAL SERVICE TOOLS2005 Expedition/Navigator New Model Technician Training 02-SEP-04 Appendix-1

Page 13

INTRODUCTIONPURPOSEThe purpose of this FORDSTAR course is to provide Ford and Lincoln/Mercury service technicians with theknowledge needed to understa


APPENDIX: ESSENTIAL SPECIAL SERVICE TOOLSNOTES2005 Expedition/Navigator New Model Technician Training02-SEP-04Appendix-2

Page 15

APPENDIX: ESSENTIAL SPECIAL SERVICE TOOLS2005 Expedition/Navigator New Model Technician Training 02-SEP-04 Appendix-3

Page 16

APPENDIX: ESSENTIAL SPECIAL SERVICE TOOLS2005 Expedition/Navigator New Model Technician Training02-SEP-04Appendix-4

Page 17 - Automatic Transmission

APPENDIX: GLOSSARY OF TERMSGLOSSARY OF TERMS2005 Expedition/Navigator New Model Technician Training 02-SEP-04 Appendix-5

Page 18

APPENDIX: GLOSSARY OF TERMSNOTES2005 Expedition/Navigator New Model Technician Training02-SEP-04Appendix-6

Page 21

INTRODUCTIONNOTES2005 Expedition/Navigator New Model Technician Training02-SEP-04Intro-6

Page 22

LESSON 1: OVERVIEWOBJECTIVES•Identify the new powertrain applications for Expedition and Navigator.•Identify exterior features.•Identify interior feat

Page 23

LESSON 1: OVERVIEWMechanical and Chassis Features Mechanical and Chassis Features•5.4L 3-Valve Triton Engine w/Variable Cam Timing.•6HP26 Automatic Tr

Page 24

LESSON 1: OVERVIEWEngine - 5.4L 5.4L 3-Valve Triton PhaserThe 2005 Expedition and Navigator are available with one engine:•New for 2005, the 5.4L 3-v


LESSON 1: OVERVIEW•Variable Cam Timing (VCT) varies cam timing to match performance demands.•Charge Motion Control Valves (CMCV) manage the flow of ai

Page 26 - Wheels and Tires

LESSON 1: OVERVIEWAutomatic Transmission 6HP26 TransmissionThe 2005 Expedition will use the 4R75E automatic transmission like the 2004 and 2005 F-150,

Page 27

LESSON 1: OVERVIEWExterior Features 2005 Navigator Exterior•New body side cladding– Bold new body side cladding is added to the 2005 Lincoln Navigator

Page 28

LESSON 1: OVERVIEW2005 Expedition Exterior•New badging for Limited and FX4 (mid 4th quarter availability).– Expedition for 2005 comes with new badging

Page 30

LESSON 1: OVERVIEWInterior Features 2005 Navigator Interior•New 6HP26 automatic transmission gear selector.– Lincoln Navigators are equipped with a ne

Page 31 - Cluster Messages

LESSON 1: OVERVIEW2005 Expedition InteriorThe 2005 Expedition receives minor trim and finish updates as:•Power fold side view miror switch (Limited on

Page 32

LESSON 1: OVERVIEWLifting and Jacking Lifting and Jacking PointsThe front and rear lifting and jacking locations are as indicated.2005 Expedition/Navi

Page 33

LESSON 1: OVERVIEWMaintenance Check Points Maintenance Check Points (Navigator Shown)Item Description Item Description1 Cabin Air Filter 6 Engine Cool

Page 34

LESSON 1: OVERVIEWNOTES2005 Expedition/Navigator New Model Technician Training02-SEP-041-12

Page 35

LESSON 2: CHASSISOBJECTIVES•Identify changes to the TPMS.•Identify new suspension system features.•Identify new drive axle/differential driveline feat

Page 36

LESSON 2: CHASSISWheels and Tires Tire Pressure Monitor•TPMS functionality is integrated into Vehicle Security Module (VSM) located in the right kick

Page 37

LESSON 2: CHASSISTPMS General Information Temperature fluctuation changes tire inflation pressure 7KPa per 12 degrees Celsius (1 psi per 10 degrees F)

Page 38

LESSON 2: CHASSISFunctionality - 2005 Model Year Sensor Wheel PackageItem Description Item Description1 Blue, 315 Mhz Tire Pressure Sensor•4-sensor sy

Page 39

LESSON 2: CHASSISSensor Description TPMS SensorItem Description Item Description1 Transmitter Case 5 Aluminum Valve2 Air Hole: Top 6 Inside: Core3 Pot

Page 40

IMPORTANT SAFETY NOTICEAppropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles,

Page 41

LESSON 2: CHASSISModule Description •TPM System integrated into Vehicle Security Module (VSM).•Module designed to:– Receive tire pressure and sensor i

Page 42

LESSON 2: CHASSISCluster Messages The following are messages that can be displayed on the message center (if equipped on Expedition models,standard on

Page 43

LESSON 2: CHASSISDTCs DTC DescriptionB1342 ECU DefectiveB2477 Module Configuration FailureB2868 Left Front Sensor FaultB2869 Right Front Sensor FaultB

Page 44


Page 45

LESSON 2: CHASSISPossible Failure Modes and Root Causes •TPMS indicator light stays ON continuously. Message center (if equipped) Displays: ‘‘Low Tire

Page 46

LESSON 2: CHASSISDriveshaft Driveshaft•Navigator 4x2 models use a unique 2-piece driveshaft.•Staked U-Joint Service.– The original u-joints are staked

Page 47

LESSON 2: CHASSISFront Drive Axle/Differential Front Drive Axle/Differential•New companion flange– The design of the front axle companion flange is un

Page 48

LESSON 3: POWERTRAINOBJECTIVES•Identify new 5.4L 3-valve engine features.•Explain the operation of the VCT system.•Explain the revised procedure for c

Page 49

LESSON 3: POWERTRAINEngine - 5.4L 5.4L 3-Valve Triton PhaserThe 2005 Expedition and Navigator are available with one engine:•New for 2005, the 5.4L 3

Page 50

LESSON 3: POWERTRAIN•Charge Motion Control Valves (CMCV) manage the flow of air into the cylinders.•Vibration-resistant ribbing and reinforcement in t

Page 51

CUSTOMER EXPECTATIONSCustomer Expectations: Service1. Make it convenient to have my vehicle 5. Provide me with a clear and thoroughserviced at your de

Page 52 - Phaser Components

LESSON 3: POWERTRAIN5.4L Three-Valve HeadThe three-valve head has two smaller intake valves and one larger exhaust valve. •The three-valve head includ

Page 53

LESSON 3: POWERTRAINAir Filter Intake Air Filter Module (IAFM)The intake air distribution and filtering design has been replaced with:•New split line

Page 54

LESSON 3: POWERTRAINMass Air Flow (MAF) SensorThe compact Mass Air Flow (MAF) sensor is located on the IAFM.•This sensor combines the Intake Air Tempe

Page 55

LESSON 3: POWERTRAINElectronic Throttle Control (ETC) ETC Throttle Body•The 5.4L 3V engine used in both the Expedition and Navigator utilizes Electron

Page 56

LESSON 3: POWERTRAINCharge Motion Control Valves (CMCV)The Charge Motion Control Valves (CMCV) are electronically controlled metal flaps at the end of

Page 57

LESSON 3: POWERTRAINCMCV MotorThe CMCVs use one electronically controlled motor to operate the CMCVs for both sides of the intake manifold.2005 Expedi

Page 58

LESSON 3: POWERTRAINCMCV Block DiagramThe CMCVs are controlled electronically by the PCM.•The inputs used by the PCM for the CMCV operation are:– Engi

Page 59

LESSON 3: POWERTRAINVCT System 5.4L Variable Cam Timing Solenoid Electrical ConnectorConventional camshafts are permanently synchronized with the engi

Page 60

LESSON 3: POWERTRAINVCT Operation VCTThe theory of operation for the 5.4L VCT is similar to the 3.9L VCT used on the Lincoln LS and 2004 FordF-150 w/5

Page 61

LESSON 3: POWERTRAINThe basics of VCT operation are: •A hydraulic timing mechanism (VCT phaser) rotates the camshafts in relation to their drive sproc

Page 62


Page 63

LESSON 3: POWERTRAIN5.4L 3-Valve Camshaft Position SensorThe VCT system requires a cam position sensor for each camshaft. •The PCM can then monitor th

Page 64

LESSON 3: POWERTRAINOil Temperature SensorThe VCT system uses a replaceable oil temperature sensor, located on the oil pan. •Engine oil temperature ha

Page 65

LESSON 3: POWERTRAINPhaser Components VCT PhaserThe VCT components include: •Camshaft phaser sprockets.•Right and left camshaft phaser sprocket assemb

Page 66

LESSON 3: POWERTRAINPhaser Oil VanesThe oil vanes create oil cavities for valve-directed oil to rotate the camshaft in relation to the crankshaft. •Oi

Page 67

LESSON 3: POWERTRAINVCT Phaser DisassembledThe VCT phaser varies camshaft timing in response to oil pressure exerted on either side of the vanes. CAUT

Page 68

LESSON 3: POWERTRAINVCT Solenoid RemovalThe VCT solenoid is serviced separately from the VCT valve body. No special tools are needed to remove thesole

Page 69

LESSON 3: POWERTRAINVCT Valve Body Oil PassagesItem Description Item Description1 Solenoid filter 5 Oil passage back into head2 Oil passage to advance

Page 70

LESSON 3: POWERTRAINLocking PinThe locking pin locks the camshaft in a fully advanced position when the engine is off. •The pin locks the phaser to th

Page 71

LESSON 3: POWERTRAINPhaser/Camshaft Removal Procedure Remove Valve CoverThe phaser replacement procedure has been revised for the 5.4L 3V engine. This

Page 72

LESSON 3: POWERTRAINSet Crankshaft Damper Notch to 1 o’clock PositionSet the crankshaft keyway to 12 o’clock. The machined notch on the back face of t

Page 73

TABLE OF CONTENTSNOTES2005 Expedition/Navigator New Model Technician Training02-SEP-04ii

Page 74

LESSON 3: POWERTRAINCam Lobe PositioningItem Description Item Description1 Intake Lobe 2 Exhaust Lobe Pointing InwardThe camshaft must be positioned w

Page 75

LESSON 3: POWERTRAINMark Crankshaft DamperThe damper spoke pointing upwards just to the left of the machined notch is the one with the keyway cut in i

Page 76

LESSON 3: POWERTRAINLoosen One TurnLoosen the camshaft phaser bolt one turn. Do not remove the bolt. CAUTION: DO NOT use an impact wrench when looseni

Page 77

LESSON 3: POWERTRAINRemove Only the Indicated FollowersWhen removing the followers, remove the exhaust followers from the exhaust manifold side of the

Page 78

LESSON 3: POWERTRAINSet Crankshaft Damper Spoke to 6 o’clock PositionRotate the marked damper spoke clockwise to the 6 o’clock position. CAUTION: It i

Page 79

LESSON 3: POWERTRAINInset Timing Chain Wedge ToolAssemble the ESST 303-636 Timing Chain Wedge to the ESST 303-637 Handle. Insert the timing chain wedg

Page 80 - Range Selection

LESSON 3: POWERTRAINLoosen #1 Camshaft Bearing Cap BoltsMark the cam caps for proper reinstallation.NOTE: The camshaft bearing caps must be installed

Page 81 - External Controls

LESSON 3: POWERTRAINRemove the Phaser BoltThe remaining followers will be loose on the lifters. Be sure to keep them in place so that the camshaft can

Page 82

LESSON 3: POWERTRAINRemove the PhaserUsing extreme care, withdraw the phaser from the nose of the camshaft. It may be necessary to slightly tip up the

Page 83

LESSON 3: POWERTRAINCam and Phaser Reassembly Seating Cam FollowersCare should be taken to ensure that the remaining followers are properly seated pri

Page 84

INTRODUCTIONFCSDTechnical TrainingThe distance learning course you are about to take is intended to give you new knowledge and information aboutdiagno

Page 85

LESSON 3: POWERTRAINPhaser Pin and Cam NotchItem Description Item Description1 Phaser Pin 2 Cam NotchIt is extremely important to align the phaser pin

Page 86

LESSON 3: POWERTRAINInstalling the Bearing CapsInstall the camshaft bearing caps in the reverse order of removal. NOTE: The camshaft bearing caps must

Page 87

LESSON 3: POWERTRAINElectronic Engine Controls Electronic Engine Controls•New integrated 4x4 strategy.– 4x4 operational strategy is now incorporated i

Page 88

LESSON 3: POWERTRAIN•New premium fuel calibration (Navigator).– The aggressive spark and fuel programming requires 91 octane (or higher) fuel for maxi

Page 89

LESSON 3: POWERTRAINFuel Tank and Lines Fuel Tank and Lines•New fuel filter– The fuel filter is located on the front side of the fuel tank. It can be

Page 90

LESSON 3: POWERTRAINEngine Special Service Tools Engine Special Service ToolsItem Description Item Description1 ESST 307-516/1 Installer, Teflon Seal

Page 91

LESSON 3: POWERTRAINAutomatic Transmission Description 6HP26 TransmissionThe 6HP26 transmission uses planetary gears with multiple clutches and electr

Page 92

LESSON 3: POWERTRAIN•shift feel.•shift scheduling.•modulated Torque Converter Clutch (TCC) applications.•engine braking.This transmission has a mechat

Page 93

LESSON 3: POWERTRAINOperation 6HP26 CutawayEngine power reaches the transmission by a torque converter with an integral converter clutch. The six forw

Page 94

LESSON 3: POWERTRAINIdentification Tag Identification TagThe identification tag is located on the left side of the case just rearward of the manual co

Page 95

INTRODUCTIONLOGGING ONYour response keypad transmits data and voice between you and the host site via telephone lines and satellite. It isyour ‘‘lifel

Page 96 - TCM Monitoring Functions

LESSON 3: POWERTRAINRange Selection Shifter PatternThe transmission has eight range positions: P, R, N, D6, D4, 3, 2 and 1.In the Park position:•There

Page 97

LESSON 3: POWERTRAINThe D6 position is the normal position for most driving conditions. It provides:•Automatic shifts 1-6 and 6-1•Apply and release of

Page 98

LESSON 3: POWERTRAINShift Patterns •Under certain conditions the transmission automatically downshifts to a lower gear range (without moving therange

Page 99

LESSON 3: POWERTRAINShift Elements Shift ElementsItem Description Item Description1 Double Planetary Gearset 6 Overdrive Clutch2 Forward Clutch 7 Low/


LESSON 3: POWERTRAINThe shift elements are engaged hydraulically. The transmission fluid pressure builds up between the cylinder andthe piston, pressi


LESSON 3: POWERTRAINMulti Plate Clutch Multi Plate ClutchItem Description Item Description1 Clutch Pack Cluster 6 Turbine Shaft2 Piston 7 Lubricating


LESSON 3: POWERTRAINFluid Pan, Gasket and Filter Fluid Pan, Gasket and FilterThe transmission fluid pan, gasket and filter is a one-piece assembly. Al

Page 103

LESSON 3: POWERTRAIN5. Start the engine. Move the transmission range selector lever through all the gear ranges, checking forengagements.6. With the e

Page 104

LESSON 3: POWERTRAINTransmission Control Module (TCM) and Main Control Valve Body Transmission Control Module (TCM) and Main Control Valve BodyThe Mai

Page 105

LESSON 3: POWERTRAINTransmission Electronic System The TCM receives input signals from certain transmission-related sensors and switches. The TCM uses

Page 106

INTRODUCTIONKEYPAD OPERATIONCALL Key •Press the CALL key if you have a question or comment. This places you in the call queue. The system indicatesyou

Page 107

LESSON 3: POWERTRAINTransmission Control Module (TCM) Transmission Control Module (TCM)The TCM is mounted on top of the main control valve body. The c

Page 108 - Module Programability

LESSON 3: POWERTRAINSolenoids SolenoidsItem Description Item Description1 SSA (EDS1) 5 SSD (EDS4)2 SSB (EDS2) 6 SSE (MV1)3 SSC (EDS3) 7 TCC (EDS6)4 PC

Page 109

LESSON 3: POWERTRAINController Area Network (CAN) Interface Controller Area Network (CAN) InterfaceFor the TCM to carry out shift point and shift qual

Page 110

LESSON 3: POWERTRAINSensors Integrated With TCM Sensors Integrated With TCMItem Description Item Description1 Output Shaft Speed (OSS) Sensor 3 Turbin

Page 111

LESSON 3: POWERTRAINTransmission Range Position Sensor Transmission Range Position SensorThe TCM uses the position of this switch, housed on the TCM a

Page 112

LESSON 3: POWERTRAINTransmission Operational Strategies Adaptive shift strategy is comprised of the following functions:•Shift Energy Management - Red


LESSON 3: POWERTRAINTCM Monitoring Functions The TCM monitors all transmission inputs and outputs to identify possible transmission failures. If a fau

Page 114

LESSON 3: POWERTRAINMonitoring The Substrate Temperature Sensor Substrate Temperature SensorThe TCM controls a number of high power solenoids and is s

Page 115

LESSON 3: POWERTRAINTransmission Cooling Transmission Cooling•New quick connect transmission oil cooler lines.– Quick connect fittings are used at the

Page 116

LESSON 3: POWERTRAIN6HP26 Transmission Special Service Tools Item Description307-552 Direct Clutch Service Fixture307-553 Front Pump Removal Tool307-5

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