1998 expedition/navigator workshop manual page 1 of 15 · 2009. 1. 4. · 31. position the lh and...

Instrument Panel

Removal

1. WARNING: To avoid accidental deployment and possible injury, the backup power supply must be depleted before repairing or replacing any air bag system components. To deplete the backup power supply energy, disconnect the battery to starter relay cable and wait one minute.

Disconnect the battery cables. 1. Disconnect the battery ground cable (14301). 2. Disconnect the battery to starter relay cable (14300) and wait one minute for the backup power supply to be depleted.

2. If equipped, remove the front floor console assembly; refer toConsole—Floor, Front.

3. Remove the instrument panel steering column cover; refer to Instrument Panel—Steering Column Cover.

4. Remove the LH and RH scuff plates.

5. Remove the LH and RH cowl side trim panels.

6. Disconnect the brake pedal position (BPP) switch electrical connector.

7. Remove the (A) radio ground and the (B) GEM/CTM ground bolts.

8. Disconnect the LH instrument panel main harness connectors. 1. Loosen the bolt. 2. Disconnect the LH instrument panel main harness connectors.

Page 1 of 151998 Expedition/Navigator Workshop Manual

1/4/2009http://www.fordtechservice.dealerconnection.com/pubs/content/~WSWJ/~MUS~LEN/20/S...

9. Remove the bulkhead wiring harness electrical connectors from inside the engine compartment. 1. Loosen the bolts. 2. Disconnect the bulkhead electrical connectors.

10. Remove the bulkhead electrical connector from the dash panel. 1. Release the six locking tabs. 2. Remove the bulkhead electrical connector from the dash panel.

11. Disconnect the air bag diagnostic monitor electrical connectors.

12. Disconnect the inertia fuel shutoff switch electrical connector.

13. Remove the RH ground bolts.



14. Disconnect the RH instrument panel main harness connectors.

15. Disconnect the electronic actuator electrical connector.

16. Disconnect the climate control head vacuum line connector.

17. Remove the instrument panel steering column opening cover reinforcement (04502) 1. Remove the nuts. 2. Remove the instrument panel steering column opening cover reinforcement

18. Disconnect the (A) air bag sliding contact electrical connectors and the (B) anti-theft sensor electrical connector.



19. Disconnect the remaining electrical connectors on the steering column.

20. If equipped, disconnect the transmission range indicator from the steering column. 1. Remove the bolt. 2. Disconnect the cable.

21. Lower the steering column. 1. Remove the nuts. 2. Lower the steering column.

22. Position the RH front fender splash shield away from the dash panel. 1. Remove the screws. 2. Position the RH front fender splash shield away from the dash panel.

23. Disconnect the antenna lead in cable from the antenna base.

24. Feed the antenna lead in cable through the cowl side panel. 1. Unseat the antenna lead in cable grommet. 2. Feed the antenna lead in cable through the cowl side panel.



25. Remove the instrument panel relay cover (044F46) 1. Remove the cover. 2. If equipped, disconnect the autolamp sensor. 3. If equipped, disconnect the sunload sensor.

26. Remove the glove compartment; refer to Glove Compartment.

27. WARNING: Always wear safety glasses when removing and handling an air bag.

WARNING: Carry a live air bag with the bag and trim cover pointed away from your body. An accidental deployment will then deploy with minimal chance of injury.

WARNING: Place a live air bag on a bench or other surface with the trim cover up.

Remove the passenger side air bag module (044A74) 1. Disconnect the electrical connector. 2. Remove the screws. 3. Remove the passenger side air bag module

28. Remove the RH assist handle screw covers.

29. Remove the RH assist handle screws.

30. Remove the RH assist handle (31406).



31. Position the LH and RH door weatherstrip seals aside.

32. Remove the RH and LH windshield side garnish mouldings (03598)

33. Remove the instrument panel reinforcement bolt below the LH corner of the glove compartment.

34. Remove the instrument panel bolts through the passenger side air bag module opening.

35. On Expedition vehicles, remove the instrument panel cowl top bolts. 1. Remove the covers. 2. Remove the bolts.

36. On Navigator vehicles, remove the instrument panel defroster grille assembly.



37. On Navigator vehicles, remove the instrument panel cowl top bolts.

38. Remove the instrument panel bolt on the relay bracket.

39. Remove the instrument panel reinforcement bolt below LH corner of the cigar lighter and power point.

40. Remove the RH instrument panel cowl side nut.

41. Remove the LH instrument panel cowl side nut.

42. Remove the instrument panel bolts through the steering column opening.



43. Remove the instrument panel to floor brace bolt.

44. NOTE: Two bullet connectors secure the instrument panel to the bulkhead.

Remove the instrument panel (04304).

Installation

1. Position the instrument panel. � Align and seat the instrument panel to the bulkhead.

2. Connect the air bag diagnostic monitor electrical connectors.

3. Connect the inertia fuel shutoff switch electrical connector.

4. Connect the bulkhead electrical connector harness.



5. Install the bulkhead wiring harness electrical connectors from inside the engine compartment.

6. Install the instrument panel bolts through the passenger side air bag module opening. � Install the RH bolt first.

7. Install the instrument panel bolts through the steering column opening.

8. Install the LH instrument panel cowl side nut.

9. Install the RH instrument panel cowl side nut.



10. On Expedition vehicles, install the instrument panel cowl top bolts. 1. Install the bolts. 2. Install the covers.

11. On Navigator vehicles, install the instrument panel cowl top bolts.

12. On Navigator vehicles, install the instrument panel defroster grille assembly.

13. Install the instrument panel bolt on the relay bracket.

14. Install the instrument panel reinforcement bolt below the LH corner of the cigar lighter and power point.

15. Install the instrument panel reinforcement bolt below the LH corner of the glove compartment.

16. Install the instrument panel to floor brace bolt.



17. Connect the radio ground and the GEM/CTM ground bolts.

18. Connect the LH instrument panel main harness connectors. 1. Connect the instrument panel main harness connectors. 2. Tighten the bolt.

19. Connect the brake pedal position (BPP) switch electrical connector.

20. Install the RH ground bolts.

21. Connect the RH instrument panel main harness connectors.

22. Install the LH and RH cowl side trim panels.



23. Install the LH and RH scuff plates.

24. Install the RH and LH windshield side garnish mouldings

25. Position the RH assist handle.

26. Install the RH assist handle screws.

27. Install the RH assist handle screw covers.

28. Install the LH and RH door weatherstrip seals into the proper position.



29. WARNING: Never probe the connectors on the air bags. Doing so may result in air bag deployment, which could result in personal injury.

WARNING: Always wear safety glasses when handling an air bag.

WARNING: Carry a live air bag with the bag and trim cover pointed away from your body. An accidental deployment will then deploy with a minimal chance of injury.

Install the passenger side air bag module. 1. Position the passenger side air bag module. 2. NOTE: Install the top bolt first.

Install the bolts. 3. Connect the electrical connector.

30. Install the glove compartment; refer to Glove Compartment.

31. Install the instrument panel relay cover. 1. If equipped, connect the sunload sensor. 2. If equipped, connect the autolamp electrical connector. 3. Install the instrument panel relay cover.

32. Position the steering column. � Install the steering column support nuts.

33. If equipped, connect the transmission range indicator to the steering column. 1. Connect the cable. 2. Install the bolt.

34. Install the instrument panel steering column opening cover reinforcement 1. Position the instrument panel steering column opening cover reinforcement 2. Install the nuts.



35. Connect the (A) air bag sliding contact electrical connectors and the (B) anti-theft sensor electrical connector.

36. Connect the remaining electrical connectors on the steering column.

37. Feed the antenna lead in cable through the cowl side panel. 1. Feed the antenna lead in cable through the cowl side panel. 2. Seat the antenna lead in cable grommet.

38. Connect the antenna lead in cable to the antenna base.



39. Install the RH front fender splash shield. 1. Position the RH front fender splash shield. 2. Install the screws.

40. Connect the electronic actuator electrical connector.

41. Connect the climate control head vacuum line connector.

42. Install the instrument panel steering column cover (044F08) ; refer to Instrument Panel—Steering Column Cover.

43. If equipped, install the front floor console assembly; refer to Console—Floor, Front.

44. NOTE: When the battery (10655) is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.

Install the battery cables.



1998 expedition/navigator workshop manual page 1 of 15 · 2009. 1. 4. · 31. position the lh and...

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