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    Ford Excursion, Expedition, Lincoln Navigator 2000-2005

    Removal & Installation 5

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    Ford Expedition And Excursion; Lincoln Navigator



    Removal & Installation
    Expedition And Navigator
    1. Disconnect the negative battery cable.
      CAUTION
      After disconnecting the negative battery cable, wait 1 minute for the SRS module to deplete its energy.

    2.  
    3. Drain the cooling system into a clean container for reuse.
    4.  
    5. Remove the instrument panel by performing the following procedure:

      Click image to see an enlarged view

      Fig. Exploded view of the instrument panel components-Ford Expedition and Lincoln Navigator



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      Fig. Exploded view of the floor console components-Ford Expedition and Lincoln Navigator



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      Fig. Remove the bulkhead electrical connectors from inside the engine compartment-Ford Expedition and Lincoln Navigator



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      Fig. Remove the audio unit ground and the GEM/CTM ground bolts-Ford Expedition and Lincoln Navigator



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      Fig. Remove the instrument panel bolts through the steering column opening-Ford Expedition and Lincoln Navigator



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      Fig. Remove the passenger side ground bolt-Ford Expedition and Lincoln Navigator



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      Fig. Detach the passenger side instrument panel main harness connectors-Ford Expedition and Lincoln Navigator



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      Fig. Remove the instrument panel bolt on the relay bracket-Ford Expedition and Lincoln Navigator



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      Fig. Remove the instrument panel bolts through the passenger side air bag module opening-Ford Expedition and Lincoln Navigator



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      Fig. Remove the instrument panel reinforcement bolt below the driver-s side corner of the glove compartment-Ford Expedition and Lincoln Navigator



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      Fig. Position the carpet aside and loosen the instrument panel floor brace-Ford Expedition and Lincoln Navigator



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      Fig. Remove the passenger side instrument panel cowl side nut-Ford Expedition and Lincoln Navigator



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      Fig. On Navigator, remove the defroster grille assembly-Ford Expedition and Lincoln Navigator



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      Fig. Remove the cowl panel mounting bolts-Ford Expedition and Lincoln Navigator



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      Fig. Remove the instrument panel -Ford Expedition and Lincoln Navigator

      1. If equipped, remove the floor console assembly.
      2.  
      3. Remove the lower steering column cover bolts and the cover.
      4.  
      5. Remove both front door scuff plates.
      6.  
      7. Remove both side cowl trim panels.
      8.  
      9. Disconnect the electrical connector from the Brake Pedal Position (BPP) switch.
      10.  
      11. Remove the radio ground and the GEM/CTM ground bolts.
      12.  
      13. Disconnect the left side instrument panel main wiring harness connector.
      14.  
      15. In the engine compartment, remove the bulkhead wiring harness connector bolts and disconnect the wiring connectors.
      16.  
      17. In the driver-s compartment, release the 6 locking tabs and remove the bulkhead electrical connector from the instrument panel.
      18.  
      19. Disconnect the air bag diagnostic monitor electrical connector.
      20.  
      21. Disconnect the inertia fuel shutoff switch electrical connector.
      22.  
      23. Remove the right side ground bolts.
      24.  
      25. Disconnect the right side instrument panel wiring harness connectors.
      26.  
      27. Disconnect the electronic blend door actuator electrical connector.
      28.  
      29. Disconnect the climate control head vacuum harness connector.
      30.  
      31. Remove the steering column opening cover reinforcement nuts and the cover reinforcement.
      32.  
      33. At the base of the steering column, disconnect the air bag sliding contact and the anti-theft sensor electrical connectors.
      34.  
      35. At the steering column, disconnect the remaining electrical connectors.
      36.  
      37. If equipped with a transmission range indicator, remove the bolt and disconnect the cable.
      38.  
      39. Remove the steering column-to-instrument panel nuts and lower the steering column.
      40.  
      41. Remove the right side front fender splash shield screws and move the shield away from the panel.
      42.  
      43. Disconnect the antenna cable from the antenna base.
      44.  
      45. Remove the instrument panel relay cover and disconnect the autolamp sensor electrical connector and/or the sunload sensor connector.
      46.  
      47. Remove the glove box.
      48.  
      49. At the passenger-s air bag module, remove the screws, disconnect the electrical connector and remove the air bag module.
      50.  

    6.  

    Place the air bag module in a safe place with the front facing upward.

    1. Remove the right side assist handle screw covers, the screws and the handle.
    2.  
    3. At both doors, pull back the weatherstrip seals and remove the windshield garnish moldings.
    4.  
    5. Remove the instrument panel reinforcement bolt below the left side corner of the glove box.
    6.  
    7. Through the air bag module opening, remove the instrument panel bolts.
    8.  
    9. On Expedition, remove the upper instrument panel cowl covers and bolts.
    10.  
    11. On Navigator, remove the instrument panel defroster grille assembly and the instrument panel cowl top bolts.
    12.  
    13. At the relay bracket, remove the instrument panel bolt.
    14.  
    15. At the lower left side of the cigar lighter, remove the instrument panel bolt.
    16.  
    17. At the both sides, remove the instrument panel-to-cowl side nuts.
    18.  
    19. At the steering column opening, remove the instrument panel bolts.
    20.  
    21. Remove the upper instrument panel floor brace bolt.
    22.  
    23. Using an assistant, remove the instrument panel.
    24.  

    1. If equipped with the 5.4L 4V engine, remove the junction block splash shield.
    2.  
    3. If equipped with the 5.4L 4V engine, remove the bolts and disconnect the cable ends from the starter relay.
    4.  
    5. If equipped with the 5.4L 4V engine, remove the junction block bracket.
    6.  
    7. Compress the holding tabs and disconnect the heater hoses from the heater core.
    8.  
    9. Remove the air conditioning plenum screw and the air conditioning plenum demister adapter.
    10.  
    11. Disconnect the vacuum line.
    12.  
    13. Remove the heater core bracket screws and the bracket.
    14.  
    15. Remove the 13 heater housing plenum camber cover screws and the heater housing plenum chamber cover.
    16.  
    17. Remove the blend door assembly from the heater housing.
    18.  
    19. Remove the heater core.

      Click image to see an enlarged view

      Fig. View of the heater core-Ford Expedition and Lincoln Navigator

    20.  

    To install:

    1. Install the heater core.
    2.  
    3. Install the blend door assembly to the heater housing.
    4.  
    5. Install the 13 heater housing plenum camber cover and the heater housing plenum chamber cover screws.
    6.  
    7. Install the heater core bracket and the bracket screws.
    8.  
    9. Connect the vacuum line.
    10.  
    11. Install the air conditioning plenum demister adapter and the air conditioning plenum screw.
    12.  
    13. Connect the heater hoses to the heater core.
    14.  
    15. Install the instrument panel by performing the following procedure:
      1. Using an assistant, install the instrument panel.
      2.  
      3. Install the upper instrument panel floor brace bolt.
      4.  
      5. At the steering column opening, install the instrument panel bolts.
      6.  
      7. At the both sides, install the instrument panel-to-cowl side nuts.
      8.  
      9. At the lower left side of the cigar lighter, install the instrument panel bolt.
      10.  
      11. At the relay bracket, install the instrument panel bolt.
      12.  
      13. On Navigator, install the instrument panel cowl top bolts and the instrument panel defroster grille assembly.
      14.  
      15. On Expedition, install the upper instrument panel cowl bolts and covers.
      16.  
      17. Through the air bag module opening, install the instrument panel bolts.
      18.  
      19. Install the instrument panel reinforcement bolt below the left side corner of the glove box.
      20.  
      21. At both doors, install the windshield garnish moldings and the weatherstrip seals.
      22.  
      23. Install the right side assist handle, the screws and the handle screw covers.
      24.  
      25. At the passenger-s air bag module, install the air bag module, connect the electrical connector and install the air bag module screws.
      26.  
      27. Install the glove box.
      28.  
      29. Connect the autolamp sensor electrical connector and/or the sunload sensor connector; then, install the instrument panel relay cover.
      30.  
      31. Connect the antenna cable to the antenna base.
      32.  
      33. Install the right side front fender splash shield and screws.
      34.  
      35. Install the steering column and the steering column-to-instrument panel nuts.
      36.  
      37. If equipped with a transmission range indicator, connect the cable and install the bolt.
      38.  
      39. At the steering column, connect the remaining electrical connectors.
      40.  
      41. At the base of the steering column, connect the air bag sliding contact and the anti-theft sensor electrical connectors.
      42.  
      43. Install the steering column opening cover reinforcement and the cover reinforcement nuts.
      44.  
      45. Connect the climate control head vacuum harness connector.
      46.  
      47. Connect the electronic blend door actuator electrical connector.
      48.  
      49. Connect the right side instrument panel wiring harness connectors.
      50.  
      51. Install the right side ground bolts.
      52.  
      53. Connect the inertia fuel shutoff switch electrical connector.
      54.  
      55. Connect the air bag diagnostic monitor electrical connector.
      56.  
      57. In the driver-s compartment, install the bulkhead electrical connector to the instrument panel.
      58.  
      59. In the engine compartment, connect the bulkhead wiring harness connectors and the install wiring connector bolts.
      60.  
      61. Connect the left side instrument panel main wiring harness connector.
      62.  
      63. Install the radio ground and the GEM/CTM ground bolts.
      64.  
      65. Connect the electrical connector to the Brake Pedal Position (BPP) switch.
      66.  
      67. Install both side cowl trim panels.
      68.  
      69. Install both front door scuff plates.
      70.  
      71. Install the lower steering column cover and the cover bolts.
      72.  
      73. If equipped, install the floor console assembly.
      74.  

    16.  
    17. Refill the cooling system.
    18.  
    19. Connect the negative battery cable.
    20.  
    21. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    22.  

     
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