Attachment III - Technical Information
OVERVIEWThis program involves inspecting the wiper motor manufacture code, then it necessary, inspecting for the presence of grease under the gear cover. Based on your inspection,
^ the vehicle may be reassembled and released, or
^ the wiper motor assembly will be replaced, or
^ [NEW] grease will be applied to the metal worm and plastic ring gears.
INSPECTION
The manufacture code is laser etched onto the cylindrical wiper motor housing. The code consists of two (2) lines of numbers. One line shows the wiper motor assembly engineering part number. The other line shows the date and time of manufacture, the assembly line it was built on (N for north or S for south) then the voltage of the motor.
The wiper motor assemblies that require additional inspection for the presence of grease on the gears were built from 8-26-05 through 10-10-05 on the south assembly line. Any motor built before or after these dates, or built on the north assembly line, requires no additional inspection and the vehicle can be immediately released. See Figure 1.
In some instances, the laser etching will be difficult to read. For these instances, the wiper motor gear cover must be removed to inspect for the presence of grease on the gear assemblies. The amount of grease will vary from motor to motor. If ANY grease is present on the worm or ring gear teeth, that wiper motor assembly requires no further service and the vehicle can be reassembled.
In most cases, the etching can be viewed with minimal removal of parts. Generally, the left wiper arm and left cowl panel grille have to be removed to view the motor and manufacture code.
Refer to the appropriate disassembly procedure for the vehicle being inspected. Then after accessing the manufacture code, refer to Inspection Results in this Attachment III.
ESCAPE, MARINER, ESCAPE HYBRID, MARINER HYBRID
NOTE:
All Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles have wiper motor assemblies that were built on the south assembly line. Therefore, it is only necessary to inspect the manufacture date code.
1. Remove the left cowl panel grille plastic pin-type retainers from along the front of the panel.
2. Carefully lift the left cowl panel to enable viewing of the wiper motor assembly and note the manufacture DATE code on the motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
3. Proceed to Inspection Results in this Attachment III.
E-SERIES
1. Remove the left wiper arm by lifting the arm slightly and releasing the lock tab, then removing the arm off of the shaft.
2. Remove the left cowl grille panel retainer screws, then remove the panel.
3. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
4. Proceed to Inspection Results in this Attachment III.
EXPEDITION, NAVIGATOR
1. Park the wipers in the highest position on the glass.
2. Lift the wiper arm nut cover. Remove the retaining nut and lift the arm off of the shaft.
3. Position aside the cowl grille panel seal.
4. Remove the pin-type retainer from the far left end of the panel, then lift the panel, disconnect the washer hose and remove the panel from the vehicle.
5. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
6. Proceed to Inspection Results in this Attachment III.
EXPLORER, MOUNTAINEER
1. Remove both wiper arms by lifting the arms slightly and releasing the lock tabs, then remove the arms off of the shafts.
2. Remove the passenger side, then the driver side cowl grille panels.
3. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
4. Proceed to Inspection Results in this Attachment III.
F-150, MARK LT
1. Remove the wiper arms by releasing the lock tabs and lifting the arms off of the shafts.
2. Remove the cowl grille panel plastic pin-type retainers (one per panel located near the fenders).
3. CAUTION: To avoid breaking the retainer hooks on the cowl grille panel, do not pull on the rear of the panel.
A) Remove the left (driver side) cowl grille panel, then the right (passenger side) panel.
B) Release the FRONT EDGE of the panel as follows:
^ Starting at the center of the vehicle, depress the forward tab and press upward on the forward edge of the panel to release it from the cowl.
^ Continuing outward from the center of the vehicle, depress the remaining forward tabs and release the rest of the panel from the cowl.
C) Release the REAR EDGE of the panel as follows:
^ Starting at the left fender, press down on the rear edge of the panel to release the retaining hook, then lightly pull the front edge of the panel forward.
^ Continuing toward the center of the vehicle, release the remaining hooks by pressing the panel down while gently pulling the panel forward.
D) Disconnect the windshield washer hose and remove the cowl grille panel from the vehicle.
4. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
5. Proceed to Inspection Results in this Attachment III.
RANGER
1. Open the hood and locate the wiper motor.
2. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
3. Proceed to Inspection Results in this Attachment III.
TAURUS
1. Park the wipers in the highest position on the glass.
2. Remove the wiper arm nut covers.
3. Remove the nuts then pull the wiper arms up off of the shafts.
4. Remove the cowl grille panel clips.
5. Remove the passenger side cowl grille panel, then the driver side panel.
6. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
7. Proceed to Inspection Results in this Attachment III.
INSPECTION RESULTS
1. If the manufacture code cannot be read (even after removing the label), refer to Gear Cover Removal and Inspection in this Attachment III.
2. The wiper motor assembly does not require additional inspection if it was built:
a) anytime on the north assembly line, or
b) before 8-26-05 or after 10-10-05 on the south assembly line. Reassemble and release the vehicle.
3. The wiper motor assembly should be inspected further only if it was built:
a) from 8-26-05 through 10-10-05 on the south assembly line.
Refer to Gear Cover Removal and Inspection in this Attachment III.
GEAR COVER REMOVAL AND INSPECTION
1. CAUTION: Use extreme care when bending the locking tabs back to remove the gear cover from the wiper motor. The cover is constructed with a glass reinforced resin which makes the tabs less flexible. Bend the tabs only far enough to release them from the lugs. Bending the tabs an excessive amount could cause them to break.
Using a small pocket screwdriver placed under the lock tab, rotate the screwdriver to disengage the tab from the lug on the motor housing. Disengage all five (5) tabs in the order indicated in Figure 2.
2. CAUTION: On Taurus, Escape Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles, the gear cover perimeter is sealed with silicone. Pry up around the perimeter of the gear cover to break the sealant from the cover.
CAUTION:
The gear cover must be squarely lifted oft of the motor housing. Any rocking or sideways motion may bend the three (3) internal electrical connector clips.
Squarely lift the gear cover off of the motor housing. Discard the covers only on Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. Retain the cover for reinstallation on all other affected models. If in the rare event a tab breaks off on of these covers, are a placement cover, part number 2L2Z-17C476-A, must be ordered.*
[NEW]* Only order a new cover if grease is found and wiper motor assembly replacement is NOT required. (See Step 3)
[NEW] 3. NOTE: QFP Grease can no longer be ordered. Dealers are to use their supply of grease on wiper motors which require it. Once the supply of grease is exhausted, wiper motors are to be replaced when no grease is found during wiper motor inspection.
Inspect the worm and ring gears for presence of grease. Any amount of grease is acceptable as long as there is some grease present on the worm and ring gears. See Figure 3.
^ If grease is present, no further service is required. Refer to Gear Cover Installation for specific cover installation procedures.
^ If no grease is present, apply a bead of grease, part number QFP, approximately 2-3 mm (1/8 in) wide and 20 mm (3/4 in) long, to the worm and ring gear mating area, beginning where the worm gear exits the motor. See Figure 3. The first tube will be shipped to dealers free of charge. DO NOT USE ANY OTHER GREASE. Then, refer to Gear Cover Installation for detailed gear cover installation procedures.
^ Refer to Attachment V for OFP Grease MSDS.
^ If grease is unavailable, replace the wiper motor assembly following the procedures in Section 501-16 of the appropriate workshop manual.
GEAR COVER INSTALLATION
NOTE:
A new gear cover, part number 1F2Z-17D532-CA, must be installed on Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. On all others, reinstall the original cover unless the locking tabs have been broken, bent or otherwise damaged, in which case, a new cover, part number 2L2Z-17C476-A, must be installed.
1. Inspect the three (3) internal electrical connector clips. All three (3) clips MUST be aligned against the plastic terminal holder. If any of the clips are misaligned or touching the motor housing, they must be straightened and positioned as shown in the illustration. See Figure 4.
2. NOTE: This step applies only to Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. For all others, proceed to Step 3.
CAUTION:
Do not use solvents or compressed air to remove the sealant from the motor gear housing. Any solvent entering the gear cavity may damage the motor. Also, remove all large pieces of sealant that enter the gear housing cavity during cleaning. Small particles of sealant left in the cavity are acceptable.
NOTE:
It is not necessary to remove the existing sealant attached to the vertical surfaces inside the gear housing.
Remove the existing sealant from the top surface of the gear housing and around each of the five (5) mounting lug areas. To avoid damaging the motor, extra care must be taken when removing sealant from the area around the internal electrical connector clips. See Figure 5.
3. Verity that the three (3) electrical spade terminals are not bent. It necessary, straighten them so that they are perpendicular to the cover as illustrated in Figure 6.
4. Make sure that the foam gasket is properly seated in the new cover as shown in Figure 6.
5. NOTE: This step applies only to Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. For all others, proceed to Step 6.
Make sure that the white cam follower arm is positioned as shown in Figure 6.
6. IMPORTANT: Position the cover on the gear housing so that each plastic locking tab is outside of the gear housing cavity and is resting over the mounting lugs. Ensure that the electrical spade terminals are lined up with the connector clips. See Figure 7.
7. Using two (2) hands, push the gear cover downward onto the gear housing uniformly, to ensure that the electrical terminals remain in alignment. Push down firmly until all five (5) locking tabs are latched correctly. See Figure 8.
8. CAUTION: If any of the locking tabs cannot be correctly latched as shown in Figure 9, contact the Special Service Support Center for further instructions. DO NOT attempt to remove the cover and reinstall it.
9. Reassemble the vehicle following the disassembly procedures in reverse order. On Taurus and Expedition/Navigator vehicles, tighten the wiper arm attaching nuts to 40 Nm (30 lb-ft).
10. IMPORTANT: Check for proper wiper motor operation in all speeds, intermittent and wash, then release the vehicle.