A/C - Rear Defroster Inoperative
TSB 08-21-510/27/08
REAR WINDOW DEFROSTER INOPERATIVE - GRID
BUTTON TERMINAL REPAIR
FORD:
2006-2009 Explorer
MERCURY:
2006-2009 Mountaineer
ISSUE
Some 2006-2009 Explorer and Mountaineer vehicles may exhibit an inoperative electric rear window defroster grid lines. This condition can be caused by rear defroster grid button terminal(s) coming loose from the conductive grid line area of the back glass.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
THE REAR WINDOW MUST BE AT A MINIMUM OF 60 0F (16 °C) BEFORE A REPAIR IS MADE.
Surface Preparation
1. The new terminal will cover the original terminal location, but must be placed so that the new terminal conductive areas will be placed on a good conductive base.
2. This area should be cleaned with steel wool or an abrasive pad to remove grime from the buss-bar. The area should then be cleaned with Motorcraft� Ultra-Clear Spray Glass Cleaner or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry and appear metallic.
3. Depending on the buss-bar condition, rigorous polishing with steel wool may be required. Please note that the entire buss-bar may be cleaned to improve appearance.
Installation Procedure
CAUTION
DO NOT USE ANY TYPE OF FLAME TORCH OR FLAME HEATED SOLDERING GUN FOR THIS PROCEDURE. TESTING INDICATED INADEQUATE HEAT GENERATION AT THE TIP AND THE EXHAUST HEAT CAN CAUSE DAMAGE TO PLASTIC TRIM PARTS IN THE AREA. USE ONLY AN ELECTRIC SOLDERING GUN WITH 100 WATTS OR MORE OF POWER. BEFORE USING THE SOLDERING GUN, BE SURE TO MELT A SMALL AMOUNT OF ROSIN CORE SOLDER TO THE TIP. THE SOLDER WILL ASSIST IN ACHIEVING BETTER HEAT TRANSFER FROM THE SOLDERING GUN TIP TO THE NEW TERMINAL.
The new terminal has pre-applied solder and flux. When the proper temperature is achieved the solder will liquefy. Use button type terminal refer to (Figure 1)
1. Place the replacement terminal over the original tab location making sure the conductive areas of the terminal will be on a good conductive area. Do not place the terminal tab foot on the original location which does not have conductive material (Figure 2).
NOTE
DEPENDING ON THE ORIGINAL TERMINAL LOCATION, AND WHETHER THE TERMINAL IS COVERED BY TRIM, WILL DETERMINE WHERE TO LOCATE THE NEW TERMINAL. SOME GRID LINE BUSS-BARS MAY ONLY ALLOW THE PLACEMENT OF THE TERMINAL ABOVE OR BELOW THE ORIGINAL TAB LOCATION DUE TO SPACE LIMITATIONS, BUT FOR MOST VEHICLE APPLICATIONS THE REPLACEMENT TAB LOCATION WILL COVER THE ORIGINAL TAB LOCATION BUT STILL ALLOW THE REPLACEMENT TAB TO ATTACH TO THE BUSS-BAR ON GOOD CONDUCTIVE MATERIAL.
2. Hold the terminal in place with an item such as regular lead pencil at a 90 degree angle from the terminal. (Holding at other than a 90 degree angle may allow the terminal to slip when the solder liquefies) (Figure 3)
3. Place the soldering gun tip on the base of the terminal near the pre-applied solder areas of the tab. Energize the soldering gun and watch for the pre-applied area of the terminal to liquefy. The solder should liquefy in approximately 40-45 seconds after heating. As soon as the solder completely changes on either side of the terminal, de-energize the soldering gun and continue to hold the terminal in place with the soldering gun and pencil for an additional thirty (30) seconds
4. Remove the soldering gun and pencil from the terminal. The terminal should be allowed to cool for another two (2) minutes before the wiring lead is attached to the terminal.
5. Attach the electrical lead connection to this terminal
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082105A 2006-2009 0.4 Hr.
Explorer/Mountaineer:
Replace one Terminal,
Includes Time To Remove
Trim Panel And, Prepare
Glass
082105B 2006-2009 0.5 Hr.
Explorer/Mountaineer:
Replace Both Terminals
Includes Time To Remove
Trim Panels And, Prepare
Glass
DEALER CODING
CONDITION
BASIC PART NO. CODE
7042006 28
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