310-00-1 Fuel System — General Information 310-00-1

SPECIFICATIONS
General Specifications (Continued)
Item Specification
General Specifications
Fuel Pressure
Item Specification
Key on, engine off 172-448 kPa (25-65 psi)
Fuel Tank Capacity
Engine running 172-448 kPa (25-65 psi)
Standard 85.2 L (22.5 gallons)

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
310-00-1 Fuel System — General Information 310-00-1

DESCRIPTION AND OPERATION

Fuel System The fuel pump is controlled by the PCM. Electrical
power is provided through the inertia fuel shutoff
The fuel system consists of:
(IFS) switch. The engines are equipped with
• the electric fuel pump which provides pressurized sequential multiport fuel injection (MFI). The PCM
fuel to the engine. is able to maintain constant fuel pressure by
• the fuel level sensor. varying fuel pump module (FPM) output. This is
accomplished by increasing or decreasing voltage
• the fuel pump inlet filter (filter sock). supplied to the tank-mounted FPM.
• a check valve which maintains system pressure
after the pump is shut off.
• a parallel pressure relief valve (with bleed port)
which maintains fuel in the system after the fuel
pump is shut off.
• a fuel pump driver module (FPDM) that controls
the fuel pump based on input received from the
powertrain control module (PCM).

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
310-00-1 Fuel System — General Information 310-00-1

GENERAL PROCEDURES
Fuel System Pressure Release 1. Remove the Schrader valve cap.

Special Tool(s)
EFI/CFI Fuel Pressure Gauge
310-012 (T80L-9974-B)

WARNING: Do not smoke or carry lighted

tobacco or open flame of any type when working
on or near any fuel related component. Highly
flammable mixtures are always present and may 2. NOTE: Drain the fuel into a suitable container.
be ignited, resulting in possible personal injury.
Install the special tool and open the valve
slowly to relieve the fuel pressure.
WARNING: Fuel in the fuel system
remains under high pressure even when the
engine is not running. Before servicing or
disconnecting any of the fuel lines or fuel system
components, the fuel system pressure must be
relieved to prevent accidental spraying of fuel,
causing personal injury or a fire hazard.

NOTE: During the repair or replacement of

fuel-related components, all liquid and vapor fuel
openings shall be capped, taped or otherwise
appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other
protective materials shall be removed prior to
installation.

Copyright  2004, Ford Motor Company

Last updated: 8/4/2004 2005 Aviator, 09/2004
310-01-1 Fuel Tank and Lines 310-01-1

SPECIFICATIONS
Torque Specifications
Description Nm lb-ft lb-in
General Specifications
Fuel tank support strap 55 41 —
Item Specification bolts
Fuel Tank Capacity Fuel filter shield bolts 10 — 89
Standard 85.2 L (22.5 gallons) Frame shield bolts 20 15 —
Inertia fuel shut off 2 — 18
(IFS) switch bolts

Copyright  2004, Ford Motor Company

Last updated: 10/7/2004 2005 Aviator, 09/2004
310-01-1 Fuel Tank and Lines 310-01-1

DESCRIPTION AND OPERATION

Fuel Tank and Lines
The fuel pump assembly consists of:
• the electric fuel pump which provides pressurized
fuel to the engine.
• the fuel level sensor.
• the fuel pump inlet filter (filter sock).
• a check valve which maintains system pressure
after the pump is shut off.
• a parallel pressure relief valve (with bleed port)
which maintains fuel in the system after the fuel
pump is shut off.
• a fuel pump driver module (FPDM) that controls
the fuel pump based on input received from the
powertrain control module (PCM).
Electrical power to the pump is supplied through the
intertia fuel shutoff (IFS) switch.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
310-01-1 Fuel Tank and Lines 310-01-1

REMOVAL AND INSTALLATION

Fuel Lines and Fuel Filter —
Exploded View

Item Part Number Description Item Part Number Description

1 — Vacuum hoses (part of 5 W500128-S Bell housing bolt
9E616) 6 W52101-S Nuts
2 9J274 Spring lock coupling 7 9A355 Fuel filter shield
3 707079-S Bolts 8 — Push connect fitting
4 5D032 Shield (Continued)
(Continued)

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
310-01-2 Fuel Tank and Lines 310-01-2
REMOVAL AND INSTALLATION (Continued)
Item Part Number Description 1. For additional information, refer to the
9 — Fuel vapor tube (part of procedures in this section.
9D676)
10 9J280 Quick connect fitting
11 9155 Fuel filter

2005 Aviator, 09/2004

310-01-1 Fuel Tank and Lines 310-01-1

REMOVAL AND INSTALLATION

Fuel Lines NOTE: During the repair or replacement of
fuel-related components, all liquid and vapor fuel
Special Tool(s) openings shall be capped, taped or otherwise
appropriately protected to prevent the ingress of dirt
Disconnect Tool, Spring Lock or other contamination. All caps, tape and other
Coupling protective materials shall be removed prior to
310-S039 (T90T-9550-S)
installation.

1. Disconnect the battery ground cable. For

additional information, refer to Section 414-02.

Disconnect Tool, Spring Lock 2. Release the fuel system pressure. For additional
Coupling (3/8 inch) information, refer to Section 310-00.
310-D004 (D87L-9280-A) or
equivalent 3. Disconnect the hose from the evaporative
emission (EVAP) canister purge valve.

4. Install the spring lock coupling disconnect tool

Disconnect Tool, Spring Lock on the fuel supply tube.
Coupling (1/2 inch)
310-D005 (D87L-9280-B) or
equivalent

Material
Item Specification
SAE 5W-20 Premium WSS-M2C930-A
Synthetic Blend Motor Oil
XO-5W20-QSP

WARNING: Do not smoke or carry lighted

tobacco or open flame of any type when working 5. Press the spring lock coupling disconnect tool
on or near any fuel-related component. Highly into the open end of the cage.
flammable mixtures are always present and may
be ignited, resulting in possible personal injury.

WARNING: Fuel in the fuel system

remains under high pressure even when the
engine is not running. Before servicing or
disconnecting any of the fuel lines or fuel system
components, the fuel system pressure must be
relieved to prevent accidental spraying of fuel,
causing personal injury or a fire hazard.

Copyright  2004, Ford Motor Company

Last updated: 8/4/2004 2005 Aviator, 09/2004
310-01-2 Fuel Tank and Lines 310-01-2
REMOVAL AND INSTALLATION (Continued)
6. NOTE: When reconnecting the spring lock 12. Install the special tool and press it into the
coupling, clean and inspect the coupling ends fitting.
and lubricate the O-rings with clean engine oil.
Separate the spring lock coupling.

13. NOTE: To install, lubricate the fuel tube fitting

with clean engine oil.
7. Remove the frame shield bolts. Separate the fittings.
• To install, tighten to 20 Nm (15 lb-ft). • To install, align the fuel line fitting and
press together until a click is heard.
8. Remove the 3 bolts and the frame shield. • Pull on the fitting to make sure it is fully
engaged, then install the safety clip.
9. Remove the bell housing bolt from the fuel tube
bracket.
• To install, tighten to 48 Nm (35 lb-ft).

10. Remove the 2 fuel filter shield nuts and the

shield.
• To install, tighten to 10 Nm (89 lb-in).

11. Disconnect the safety clip from the fuel tube at

the fuel filter.

14. Disconnect the fuel vapor tube from the fuel

vapor tee and remove the fuel tubes.

15. To install, reverse the removal procedure.

2005 Aviator, 09/2004

310-01-1 Fuel Tank and Lines 310-01-1

REMOVAL AND INSTALLATION

Fuel Filter

WARNING: Do not smoke or carry lighted

tobacco or open flame of any type when working
on or near any fuel related component. Highly
flammable mixtures are always present and may
be ignited, resulting in possible personal injury.

WARNING: Fuel in the fuel system

remains under high pressure even when the
engine is not running. Before servicing or
disconnecting any of the fuel lines or fuel system
components, the fuel system pressure must be 6. Install the special tool and press it into the
relieved to prevent accidental spraying of fuel, fitting.
causing personal injury or a fire hazard.

NOTE: During the repair or replacement of

fuel-related components, all liquid and vapor fuel
openings shall be capped, taped or otherwise
appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other
protective materials shall be removed prior to
installation.

1. Disconnect the battery ground cable. For

additional information, refer to Section 414-02.

2. Release the fuel system pressure. For additional

information, refer to Section 310-00.
7. NOTE: To install, lubricate the fuel fitting with
3. Remove the 3 frame shield bolts and the shield. clean engine oil.
• To install, tighten to 20 Nm (15 lb-ft). Separate the fittings.
• To install, align the fuel line fitting and
4. Remove the fuel filter shield nuts and the press together until a click is heard.
shield. • Pull on the fitting to make sure it is fully
• To install, tighten to 10 Nm (89 lb-in). engaged, then install the safety clip.

5. Disconnect the safety clip from the fuel tube at

the fuel filter.

Copyright  2004, Ford Motor Company

Last updated: 8/4/2004 2005 Aviator, 09/2004
310-01-2 Fuel Tank and Lines 310-01-2
REMOVAL AND INSTALLATION (Continued)
8. Unclip the tab on the fuel filter quick connect 10. Separate the fuel filter quick connect fitting.
fitting.

11. Remove the fuel filter.

9. Depress the tabs and press the clip downward.
12. To install, reverse the removal procedure.

2005 Aviator, 09/2004

310-01-1 Fuel Tank and Lines 310-01-1

REMOVAL AND INSTALLATION

Fuel Tank and Filler Pipe — Exploded
View

Item Part Number Description Item Part Number Description

1 9030 Fuel filler cap 5 — Vapor tube connector (part of
2 N807605S Screws 9E616)
3 W704901S Bolts 6 W525397S Clamp
4 9J274 Push connect fitting 7 9010 Fuel tank
(Continued) 8 W520113S Nut
(Continued)

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
310-01-2 Fuel Tank and Lines 310-01-2
REMOVAL AND INSTALLATION (Continued)
Item Part Number Description Item Part Number Description
9 9054 Front support strap 15 9034 Fuel filler pipe
10 W706496S Bolt 16 14A464 Fuel pump electrical
11 9057 Rear support strap connector
12 9K324 Fuel vapor hose 17 9010 Fuel tank
13 — Fuel vapor hose (part of 18 9J280 Quick connect fitting
9034)
14 — Fuel vapor hose (part of 1. For additional information, refer to the
9034) procedures in this section.
(Continued)

2005 Aviator, 09/2004

310-01-1 Fuel Tank and Lines 310-01-1

REMOVAL AND INSTALLATION

Fuel Tank NOTE: During the repair or replacement of
fuel-related components, all liquid and vapor fuel
Special Tool(s) openings shall be capped, taped or otherwise
appropriately protected to prevent the ingress of dirt
Fuel Tank Drain Hose or other contamination. All caps, tape and other
310-F013 protective materials shall be removed prior to
installation.

1. With the vehicle in NEUTRAL, position it on a

hoist. For additional information, refer to
Section 100-02.
30 Gallon Hand-Operated Fuel
Tanker 2. Disconnect the battery ground cable. For
034-00002 or equivalent additional information, refer to Section 414-02.

3. Release the fuel system pressure. For additional

information, refer to Section 310-00.

Disconnect Tool, Spring Lock 4. Remove the driveshaft. For additional

Coupling information, refer to Section 205-00.
310-S039
5. Disconnect the fuel filler hose from the fuel
filler intermediate pipe.

Material
Item Specification
SAE 5W-20 Premium WSS-M2C930-A
Synthetic Blend Motor Oil
XO-5W20-QSP

WARNING: Do not smoke or carry lighted

tobacco or open flame of any type when working
on or near any fuel related component. Highly
flammable mixtures are always present and may
be ignited, resulting in possible personal injury.
6. Use the special tool and a suitable tanker and
WARNING: Fuel in the fuel system siphon the fuel through the fuel filler hose.
remains under high pressure even when the
engine is not running. Before servicing or
disconnecting any of the fuel lines or fuel system
components, the fuel system pressure must be
relieved to prevent accidental spraying of fuel,
causing personal injury or a fire hazard.

Copyright  2004, Ford Motor Company

Last updated: 8/4/2004 2005 Aviator, 09/2004
310-01-2 Fuel Tank and Lines 310-01-2
REMOVAL AND INSTALLATION (Continued)
7. Remove the fuel tank skid plate, if equipped.

8. Disconnect the safety clip from the fuel supply

tube.

11. Disconnect the vapor tube connector.

12. Use a suitable jack to support the fuel tank.

9. Install the special tool and press it into the

fitting.

13. Remove the nut from the front fuel tank support
strap.
• To install, tighten to 55 Nm (41 lb-ft).
10. NOTE: To install, lubricate the fuel fitting with 14. Remove the bolt from the rear fuel tank support
clean engine oil. strap.
Separate the fittings. • To install, tighten to 55 Nm (41 lb-ft).
• To install, align the fuel line fitting and
press together until a click is heard. 15. Disconnect the fuel vapor hose from the fuel
• Pull on the fitting to make sure it is fully vapor vent valve.
engaged, then install the safety clip. • To install, lightly lube with clean engine oil.

16. Disconnect the fuel filler pipe hose from the

fuel vapor tee.
• To install, lightly lube with clean engine oil.

17. Disconnect the fuel pump electrical connector.

18. Disconnect the vapor tube connector.

2005 Aviator, 09/2004

310-01-3 Fuel Tank and Lines 310-01-3
REMOVAL AND INSTALLATION (Continued)
19. Remove the fuel tank. 20. To install, reverse the removal procedure.

2005 Aviator, 09/2004

310-01-1 Fuel Tank and Lines 310-01-1

REMOVAL AND INSTALLATION

Fuel Tank Filler Pipe 6. Remove the 2 fuel filler pipe-to-frame bolts.
• To install, tighten to 20 Nm (15 lb-ft).
Material
7. Disconnect the fuel filler pipe-to-fuel tank hose.
Item Specification
SAE 5W-20 Premium WSS-M2C930-A 8. Disconnect the vapor tube from the dust
Synthetic Blend Motor Oil separator.
XO-5W20-QSP

All vehicles 9. Disconnect the rear axle vent hose.

Early build vehicles

WARNING: Do not smoke or carry lighted
tobacco or open flame of any type when working 10. NOTE: Access the fuel vapor tube through the
on or near any fuel related component. Highly RH rear wheel well.
flammable mixtures are always present and may
be ignited, resulting in possible personal injury. Disconnect the fuel vapor tube from the fuel
vapor tee.
WARNING: Fuel in the fuel system • Unclip the hose retainer from the fuel tank
remains under high pressure even when the shield.
engine is not running. Before servicing or
disconnecting any of the fuel lines or fuel system Late build vehicles
components, the fuel system pressure must be
relieved to prevent accidental spraying of fuel, 11. NOTE: Body panel and fuel door removed for
causing personal injury or a fire hazard. clarity.
NOTE: During the repair or replacement of Depress the 2 tabs on the fuel vapor vent tube
fuel-related components, all liquid and vapor fuel in the fuel filler door pocket and disconnect the
openings shall be capped, taped or otherwise fuel vapor vent tube from the inner fenderwell.
appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other
protective materials shall be removed prior to
installation.

1. With the vehicle in NEUTRAL, position it on a

hoist. For additional information, refer to
Section 100-02.

2. Disconnect the battery ground cable. For

additional information, refer to Section 414-02.

3. Release the fuel system pressure. For additional

information, refer to Section 310-00.
All vehicles
4. Remove the fuel filler cap.
12. Remove the fuel filler pipe.
5. Remove the 3 fuel filler pipe mounting screws.
• To install, tighten to 2 Nm (18 lb-in). 13. To install, reverse the removal order.

Copyright  2004, Ford Motor Company

Last updated: 10/27/2004 2005 Aviator, 09/2004
310-01-1 Fuel Tank and Lines 310-01-1

REMOVAL AND INSTALLATION

Fuel Pump Module WARNING: Do not smoke or carry lighted
tobacco or open flame of any type when working
Special Tool(s) on or near any fuel related component. Highly
flammable mixtures are always present and may
Wrench, Fuel Tank Lock Ring
310-075 be ignited, resulting in possible personal injury.

WARNING: Fuel in the fuel system

remains under high pressure even when the
engine is not running. Before servicing or
disconnecting any of the fuel lines or fuel system
components, the fuel system pressure must be
relieved to prevent accidental spraying of fuel,
causing personal injury or a fire hazard.

NOTE: During the repair or replacement of

fuel-related components, all liquid and vapor fuel
openings shall be capped, taped or otherwise
appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other
protective materials shall be removed prior to
installation.

1. With the vehicle in NEUTRAL, position it on a

hoist. For additional information, refer to
Section 100-02.

2. Disconnect the battery ground cable. For

additional information, refer to Section 414-02.

3. Release the fuel system pressure. For additional

information, refer to Section 310-00.

4. Remove the driveshaft. For additional

information, refer to Section 205-00.

5. Disconnect the fuel filler hose from the fuel

filler intermediate pipe.

Item Part Number Description

1 14A464 Fuel pump electrical
connector
2 9A307 Fuel pump lock ring
3 9H307 Fuel pump module
4 9417 Fuel pump gasket

Copyright  2004, Ford Motor Company

Last updated: 8/4/2004 2005 Aviator, 09/2004
310-01-2 Fuel Tank and Lines 310-01-2
REMOVAL AND INSTALLATION (Continued)
6. Using the special tool and a suitable tanker, 9. Using the special tool, remove the fuel pump
siphon the fuel through the fuel filler hose. module and gasket from the fuel tank.
• Clean and inspect gasket and replace if
necessary.
• To install, tighten to 90 Nm (66 lb-ft).

7. Remove the fuel tank skid plate, if equipped.

8. Remove the fuel tank. For additional

information, refer to Fuel Tank in this section.
10. To install, reverse the removal procedure.

2005 Aviator, 09/2004

310-01-1 Fuel Tank and Lines 310-01-1

REMOVAL AND INSTALLATION

Inertia Fuel Shutoff (IFS) Switch

Item Part Number Description 2. Remove the RH interior kick panel.

1 — Scuff plate (part of
71832000) 3. Disconnect the inertia fuel shutoff (IFS) switch
electrical connector.
2 — Scuff plate (part of
71832000)
4. Remove the IFS mounting bolts.
3 7802348-A Interior kick panel
4 — Inertia fuel shutoff (IFS) • To install, tighten to 2 Nm (18 lb-in).
switch electrical connector
5. Remove the IFS switch.
5 W504148-S Bolts
6 9341 Inertia fuel shutoff (IFS) 6. To install, reverse the removal procedure.
switch

1. Remove the RH door sill scuff plates.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
310-02-1 Acceleration Control 310-02-1

SPECIFICATIONS

Torque Specifications
Description Nm lb-in
Accelerator cable bracket bolt 10 89

Copyright  2004, Ford Motor Company

Last updated: 6/29/2004 2005 Lincoln Aviator, 09/2004
310-02-1 Acceleration Control 310-02-1

DESCRIPTION AND OPERATION

Acceleration Control WARNING: Make sure surrounding
The acceleration control consists of the pedal and components such as wiring, hoses, sound
shaft assembly, accelerator cable and accelerator insulation and floor carpeting are not contacting
cable bracket. the sliding inner cable of the accelerator pedal
and shaft. Failure to follow these instructions
may result in personal injury.
The throttle is controlled by an accelerator cable
attached to the accelerator pedal and shaft. The
accelerator pedal and shaft should travel smoothly
from the IDLE to the WIDE-OPEN THROTTLE
positions. Hesitation on return or prevention of
return to the IDLE position must not occur

Copyright  2004, Ford Motor Company

Last updated: 6/29/2004 2005 Lincoln Aviator, 09/2004
310-02-1 Acceleration Control 310-02-1

DIAGNOSIS AND TESTING

Acceleration Control Visual Inspection Chart
Mechanical
Inspection and Verification
• Damaged accelerator pedal and shaft
1. Verify the customer’s concern by operating the • Damaged linkage
acceleration control system to duplicate the • Damaged accelerator cable
condition. • High engine idle speed
• Damaged throttle body
2. Inspect to determine if any of the following • Damaged or binding adjustable pedal assembly
mechanical concerns apply.
3. If the inspection reveals an obvious concern
that can be readily identified, repair it as
required.
4. If the concern remains after the inspection,
determine the symptom(s) and GO to Symptom
Chart.

Symptom Chart

SYMPTOM CHART
Condition Possible Sources Action
• Excessive effort needed to • Worn accelerator lever pivot • INSTALL a new accelerator
depress accelerator pedal and bushing. pedal and shaft.
shaft
• Accelerator cable binding. • INSTALL a new accelerator
cable. REFER to Accelerator
Cable Bracket in this section..
• Worn or damaged throttle • INSTALL a new throttle
body. body. REFER to Section
303-04.
• Accelerator pedal and shaft • Frayed or binding accelerator • INSTALL a new accelerator
feels rough or raspy cable. cable. REFER to Accelerator
Cable Bracket in this section..
• Worn or damaged throttle • INSTALL a new throttle
body. body. REFER to Section
303-04.
• Accelerator pedal and shaft • Kinked accelerator cable. • INSTALL a new accelerator
bind or stick cable. REFER to Accelerator
Cable Bracket in this section.
• Foreign object caught in • CHECK the accelerator pedal
accelerator pedal linkage. linkage. REMOVE any
foreign objects.
• Worn or damaged throttle • INSTALL a new throttle
body. body. REFER to Section
303-04.

Copyright  2004, Ford Motor Company

Last updated: 6/29/2004 2005 Lincoln Aviator, 09/2004
310-02-2 Acceleration Control 310-02-2

DIAGNOSIS AND TESTING (Continued)

SYMPTOM CHART (Continued)
Condition Possible Sources Action
• High engine idle speed • Kinked accelerator cable. • INSTALL a new accelerator
cable. REFER to Accelerator
Cable Bracket in this section.
• Foreign object caught in • CHECK the accelerator pedal
accelerator pedal linkage. linkage. REMOVE any
foreign objects.
• Incorrect engine idle speed. • REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual for diagnosis
and testing of the idle control
system.
• Adjustable accelerator pedal • Foreign object caught in • CHECK the accelerator pedal
and shaft does not adjust accelerator linkage. linkage. REMOVE any
foreign objects.
• Accelerator pedal assembly • CHECK that the adjustable
drive cable disconnected or pedal assembly drive cable is
broken. connected to the accelerator
pedal and shaft assembly.
• Adjustable pedal assembly • REFER to Section 206-00 for
drive motor. adjustable pedal assembly
diagnostics.

2005 Lincoln Aviator, 09/2004

310-02-1 Acceleration Control 310-02-1

REMOVAL AND INSTALLATION

Accelerator Control System
Components — Exploded View

Item Part Number Description

1 9737 Accelerator cable return
spring
2 9A758 Accelerator cable
3 9A825 Speed control cable
4 N807309-S Bolts
5 9728 Accelerator cable bracket

1. For additional information, refer to the

procedures in this section.

Copyright  2004, Ford Motor Company

Last updated: 6/29/2004 2005 Lincoln Aviator, 09/2004
310-02-1 Acceleration Control 310-02-1

REMOVAL AND INSTALLATION

Accelerator Cable 3. Disconnect the accelerator cable from the
throttle body linkage.
Removal and Installation
4. Squeeze the tabs and remove the accelerator
cable from the bracket.
1. Remove the accelerator cable from the rubber
plunger.

5. Pull the accelerator cable boot to the UNLOCK

position and remove the accelerator cable.
2. Position the rubber plunger rearward and
remove the cable from the accelerator pedal.

Copyright  2004, Ford Motor Company

Last updated: 6/29/2004 2005 Lincoln Aviator, 09/2004
310-02-1 Acceleration Control 310-02-1

REMOVAL AND INSTALLATION

Accelerator Cable Bracket 3. Squeeze the tabs and remove the speed control
cable from the accelerator cable bracket.
Removal and Installation
4. Disconnect the accelerator cable return spring
from the accelerator cable bracket.
1. Disconnect the accelerator cable and the speed
control cable (if equipped) from the throttle 5. Remove the bolts and the accelerator cable
body linkage. bracket.
2. Squeeze the tabs and remove the accelerator • To install, tighten to 10 Nm (89 lb-in).
cable from the bracket.

Copyright  2004, Ford Motor Company

Last updated: 6/29/2004 2005 Lincoln Aviator, 09/2004
310-03-1 Speed Control 310-03-1

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Speed control actuator 9 — 80
bracket-to-vehicle bolts
Speed control 12 9 —
actuator-to-bracket
screws
Speed control switch 7 — 62
screws

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
310-03-1 Speed Control 310-03-1

DESCRIPTION AND OPERATION

Speed Control Normally, when the brake pedal is applied, the
speed control module deactivates the speed control
The speed control system is designed to maintain
system. Under increased brake pedal effort, the
vehicle speed between 48 and 200 km/h (30 and
speed control deactivator switch, a normally closed
125 mph).
switch, opens and removes voltage to the speed
control actuator clutch, releasing the throttle
independently of the speed control module

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
310-03-1 Speed Control 310-03-1

DIAGNOSIS AND TESTING

Speed Control • speed control deactivator switch
Refer to Wiring Diagrams Cell 31, Speed Control • speed control switches
for schematic and connector information.
• vehicle speed signal (VSS)
Special Tool(s) The input to the speed control actuator comes from
73III Automotive Meter the PCM.
105-R0057 or equivalent The output of the speed control actuator is through
the speed control cable. The speed control cable
then positions the throttle as requested.
Inspection and Verification
1. Verify the customer concern by operating the
Worldwide Diagnostic System speed control to duplicate the condition.
(WDS) 2. Verify the speedometer operates correctly
Vehicle Communication Module without speed control by test driving the
(VCM) with appropriate vehicle. If the speedometer does not operate
adapters, or equivalent
diagnostic tool correctly, refer to Section 413-01.
3. Verify the stoplamps operate correctly with the
ignition switch in the OFF position. If the
Diagnostic Tool, Restraint stoplamps do not operate correctly, refer to
System (2 required) Section 417-01.
418-F395 (014-R1079)
4. Verify the brake warning indicator is operating
correctly. If the brake warning indicator is not
operating correctly, refer to Section 413-01.
5. Visually inspect for obvious signs of
mechanical or electrical damage.
Principles of Operation
Visual Inspection Chart
The stoplamp switch is normally closed to ground.
When the brake pedal is applied with the speed Mechanical Electrical
control system engaged, the stoplamp switch closes • Speed control cable • Battery junction box
(to battery voltage), putting the speed control in • Throttle lever (BJB) fuse(s):
stand-by mode. • Speed control actuator — 37 (15A)
• Stoplamp switch — 14 (15A) (with
NOTE: A redundant brake deactivator, the speed • Speed control stability assist)
control deactivator switch, is provided as an deactivator switch — 45 (2A) (without
additional safety feature. stability assist)
• Circuitry
NOTE: The speed control module is integral to the • PCM
powertrain control module (PCM).
The clockspring provides the electrical interface
6. If the concern remains after the inspection,
between the steering column wiring and the speed
connect the diagnostic tool to the data link
control switches in the steering wheel.
connector (DLC), located beneath the
The inputs to the PCM for the speed control system instrument panel, and select the vehicle to be
are the: tested from the diagnostic tool menu. If the
• anti-lock brake (ABS) module diagnostic tool does not communicate with the
vehicle:
• digital transmission range (TR) sensor
• check that the program card is correctly
installed.
• check the connections to the vehicle.

Copyright  2004, Ford Motor Company

Last updated: 10/7/2004 2005 Aviator, 09/2004
310-03-2 Speed Control 310-03-2
DIAGNOSIS AND TESTING (Continued)
• check the ignition switch position. • System passed, retrieve and record the
7. If the diagnostic tool still does not communicate continuous diagnostic trouble codes (DTCs),
with the vehicle, refer to the diagnostic tool erase the continuous DTCs, and carry out
operating manual. the KOEO Test.
8. Carry out the diagnostic tool data link test. If 9. If the DTCs retrieved are related to the concern,
the diagnostic tool responds with: go to the Powertrain Control Module (PCM)
Diagnostic Trouble Code (DTC) Index to
• SCP or UBP circuits fault; all electronic continue diagnosis.
control units no response/not equipped, refer
to Section 418-00. 10. If no DTCs related to the concern are retrieved,
GO to Symptom Chart to continue diagnosis.
• No response/not equipped for PCM, refer to
the Powertrain Control/Emissions Diagnosis NOTE: DTC P0703 and DTC P1572 must be
(PC/ED) manual. repaired before any other DTC.

Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) Index

DTC Description Source Action
P0500 Vehicle Speed Error Powertrain Control Module REFER to the Powertrain
(PCM) Control/Emissions
Diagnosis (PC/ED) manual.
P1565 Speed Control Command PCM GO to Pinpoint Test A.
Switches High/Out of
Range
P1566 Speed Control Command PCM GO to Pinpoint Test B.
Switches Low/Out of
Range
P1567 NGSC Drive Fault Output PCM GO to Pinpoint Test C.
Circuit
P1568 NGSC Actuator Self-Test PCM GO to Pinpoint Test D.
Failure Unable to Hold
Speed
P1572 Brake On/Off Failure PCM GO to Pinpoint Test E.
P0703 Brake Switch Input PCM GO to Pinpoint Test E.
Malfunction

Symptom Chart

Symptom Chart
Condition Possible Sources Action
• No communication with the • Circuitry • REFER to the Powertrain
powertrain control module • PCM Control/Emissions Diagnosis
(PCM) (PC/ED) manual.
• The speed control switch is • Speed control switch • INSTALL a new speed
inoperative — no DTCs control switch. REFER to
Speed Control Switch in this
section. TEST the system for
normal operation.

2005 Aviator, 09/2004

310-03-3 Speed Control 310-03-3
DIAGNOSIS AND TESTING (Continued)
Symptom Chart (Continued)
Condition Possible Sources Action
• The speed control is • Circuitry • GO to Pinpoint Test F.
inoperative — no DTCs • Speed control switch
• Speed control deactivator
switch
• Digital transmission range
(TR) sensor
• Charging system.
• Powertrain control module
(PCM).
• The speed control indicator • Instrument cluster • GO to Pinpoint Test G.
lamp is always on • Powertrain control module
(PCM)

Connector Circuit Reference

Speed Control Actuator C122

Pin Number(s) Circuit Designation/Description Normal Condition/Measurement

1 1139 (VT/YE) B+ voltage RUN/START Greater than 10 volts with the key in the
position RUN/START positions.
2 376 (BN/WH) speed control motor 0 volts, less than 5 ohms between the speed
control actuator and the PCM. Greater than
10,000 ohms between the speed control
actuator and ground.
3 265 (LG/WH) speed control motor 0 volts, less than 5 ohms between the speed
control actuator and the PCM. Greater than
10,000 ohms between the speed control
actuator and ground.
4 264 (WH/LB) speed control motor 0 volts, less than 5 ohms between the speed
control actuator and the PCM. Greater than
10,000 ohms between the speed control
actuator and ground
5 133 (BK) speed control clutch 0 volts, less than 5 ohms between the speed
control actuator and the PCM. Greater than
10,000 ohms between the speed control
actuator and ground.
6 307 (BK/YE) speed control deactivator Greater than 10 volts with the brake pedal
switch input released.

2005 Aviator, 09/2004

310-03-4 Speed Control 310-03-4
DIAGNOSIS AND TESTING (Continued)
Digital Transmission Range (TR) Sensor C167

Pin Number(s) Circuit Designation/Description Normal Condition/Measurement

2 359 (GY/RD) digital signal return 0 volts, less than 5 ohms between the digital
TR sensor and the PCM.
4 1144 (YE/BK) digital TR sensor signal 0 volts, less than 5 ohms between the digital
TR sensor and the PCM.

Powertrain Control Module (PCM) C175b

Pin Number(s) Circuit Designation/Description Normal Condition/Measurement

28 307 (BK/YE) speed control deactivator Greater than 10 volts with the brake pedal
switch input released.
29 264 (WH/LB) speed control motor 0 volts, less than 5 ohms between the PCM
and the speed control actuator. Greater than
10,000 ohms between the PCM and ground.
36 265 (LG/WH) speed control motor 0 volts, less than 5 ohms between the PCM
and the speed control actuator. Greater than
10,000 ohms between the PCM and ground.
40 511 (LG) brake pedal position 0 volts with the brake pedal released.
45 133 (BK) speed control clutch 0 volts, less than 5 ohms between the PCM
and the speed control actuator. Greater than
10,000 ohms between the PCM and ground.
46 376 (BN/WH) speed control motor 0 volts, less than 5 ohms between the PCM
and the speed control actuator. Greater than
10,000 ohms between the speed control
actuator and ground.

2005 Aviator, 09/2004

310-03-5 Speed Control 310-03-5
DIAGNOSIS AND TESTING (Continued)
Pin Number(s) Circuit Designation/Description Normal Condition/Measurement
56 848 (DG/OG) speed control return 0 volts, less than 5 ohms between the
clockspring and the PCM. Greater than
10,000 ohms between the PCM and ground.
57 151 (LB/BK) speed control signal Less than 5 ohms between the clockspring
and the PCM. Greater than 10,000 ohms
between the PCM and ground.

Powertrain Control Module (PCM) C175t

Pin Number(s) Circuit Designation/Description Normal Condition/Measurement

17 359 (GY/RD) digital TR sensor signal return 0 volts, less than 5 ohms between the PCM
and the digital TR sensor.
22 1144 (YE/BK) digital TR sensor signal 0 volts, less than 5 ohms between the PCM
and the digital TR sensor.

Clockspring C218a

Pin Number(s) Circuit Designation/Description Normal Condition/Measurement

4 151 (LB/BK) speed control signal 0 volts, less than 5 ohms between the
clockspring and the PCM. Greater than
10,000 ohms between the clockspring and
ground.
5 848 (DG/OG) speed control return 0 volts, less than 5 ohms between the
clockspring and the PCM.

2005 Aviator, 09/2004

310-03-6 Speed Control 310-03-6
DIAGNOSIS AND TESTING (Continued)
Speed Control Deactivator Switch C2227

Pin Number(s) Circuit Designation/Description Normal Condition/Measurement

1 10 (LG/RD) B+ voltage Greater than 10 volts with key ON or OFF.
2 307 (BK/YE) speed control deactivator Greater than 10 volts with the brake pedal
switch input released.

Pinpoint Test A: DTC P1565 — The Speed Possible Causes

Control Command Switches HIGH/OUT of
Range • circuit 151 (LB/BK) short to voltage
• circuit 848 (DG/OG) open
Normal Operation
• clockspring
Under normal operation the powertrain control
module (PCM) sends a signal through circuit 151 • PCM
(LB/BK) to the speed control switches which passes • speed control switch
through the clockspring. The return signal is sent • horn switch wiring harness
through circuit 848 (DG/OG) and the clockspring.
PINPOINT TEST A: DTC P1565 — SPEED CONTROL COMMAND SWITCHES HIGH/OUT OF RANGE
Test Step Result / Action to Take
A1 CHECK FOR A SHORT TO VOLTAGE
• Key in OFF position.
• Disconnect: Powertrain Control Module (PCM) C175b.
• Key in ON position.
• Measure the voltage between the PCM C175b-57, circuit 151
(LB/BK), harness side and ground.

Yes
GO to A7.
No
• Is any voltage present? GO to A2.
A2 CHECK FOR AN OPEN CIRCUIT
• Key in OFF position.
(Continued)

2005 Aviator, 09/2004

310-03-7 Speed Control 310-03-7
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST A: DTC P1565 — SPEED CONTROL COMMAND SWITCHES HIGH/OUT OF RANGE
(Continued)
Test Step Result / Action to Take
A2 CHECK FOR AN OPEN CIRCUIT (Continued)
• Measure the resistance between the PCM C175b-57, circuit 151
(LB/BK), harness side and the PCM C175b-56, circuit 848,
(DG/OG), harness side.

Yes
GO to A4.
No
• Is the resistance greater than 10,000 ohms? GO to A3.
A3 CHECK FOR CORRECT PCM OPERATION
• Disconnect all the PCM connectors. Yes
• Check for: INSTALL a new PCM. REFER to Section
• corrosion 303-14. TEST the system for normal
• pushed-out pins operation.
• Connect all the PCM connectors and make sure they are seated No
correctly. The system is operating correctly at this
• Operate the system and verify the concern is still present. time. The concern may have been caused
• Is the concern still present? by a loose or corroded connector. CLEAR
the DTCs. REPEAT the self-test.
A4 CHECK CIRCUIT 848 (DG/OG) FOR AN OPEN
• Disconnect: Clockspring C218a.
• Measure the resistance between the PCM C175b-56, circuit 848
(DG/OG), harness side and the clockspring C218a-5, circuit 848
(DG/OG), harness side.

Yes
GO to A5.
No
REPAIR the circuit. CLEAR the DTCs.
• Is the resistance less than 5 ohms? REPEAT the self-test.
A5 CHECK THE CLOCKSPRING
• Remove the driver air bag module. Refer to Section 501-20B.
(Continued)

2005 Aviator, 09/2004

310-03-8 Speed Control 310-03-8
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST A: DTC P1565 — SPEED CONTROL COMMAND SWITCHES HIGH/OUT OF RANGE
(Continued)
Test Step Result / Action to Take
A5 CHECK THE CLOCKSPRING (Continued)
• Measure the resistance between the clockspring C 218a pin 5,
component side and the top of the clockspring pin 2, component
side.

Yes
GO to A6.
No
INSTALL a new clockspring. REFER to
Section 501-20B. INSTALL the driver air
bag module. Refer to Section 501-20B.
• Is the resistance less than 5 ohms? CLEAR the DTCs. REPEAT the self-test.
A6 CHECK THE SPEED CONTROL SWITCH
• Disconnect: Speed Control Switch.
• Measure the resistance between the speed control switch pin 1,
component side and the speed control switch pin 2, component
side.

Yes
REPAIR or INSTALL a new horn switch
wiring harness. INSTALL the driver air bag
module. Refer to Section 501-20B. CLEAR
the DTCs. REPEAT the self-test.
No
INSTALL a new speed control switch.
REFER to Speed Control Switch in this
section. INSTALL the driver air bag
module. Refer to Section 501-20B.
• Is the resistance approximately 4,300 ohms? CLEAR the DTCs. REPEAT the self-test.
A7 CHECK CIRCUIT 151 (LB/BK) FOR A SHORT TO VOLTAGE
• Key in OFF position.
• Disconnect: Clockspring C218a.
• Key in ON position.
(Continued)

2005 Aviator, 09/2004

310-03-9 Speed Control 310-03-9
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST A: DTC P1565 — SPEED CONTROL COMMAND SWITCHES HIGH/OUT OF RANGE
(Continued)
Test Step Result / Action to Take
A7 CHECK CIRCUIT 151 (LB/BK) FOR A SHORT TO VOLTAGE
(Continued)
• Measure the voltage between the PCM C175b-57, circuit 151
(LB/BK), harness side and ground.

Yes
REPAIR the circuit. CLEAR the DTCs.
REPEAT the self-test.
No
INSTALL a new clockspring. REFER to
Section 501-20B. CLEAR the DTCs.
• Is any voltage present? REPEAT the self-test.

Pinpoint Test B: DTC P1566 — The Speed Possible Causes

Control Command Switches LOW/OUT of
Range • circuit 151 (LB/BK) short to ground or short to
circuit 848 (DG/OG)
Normal Operation • circuit 848 (DG/OG) short to ground or short to
Under normal operation the powertrain control circuit 151 (LB/BK)
module (PCM) sends a signal through circuit 151 • clockspring
(LB/BK) to the speed control switches which passes
through the clockspring. The return signal is sent • PCM
through circuit 848 (DG/OG) and the clockspring. • speed control switches
PINPOINT TEST B: DTC P1566 — SPEED CONTROL COMMAND SWITCHES LOW/OUT OF RANGE
Test Step Result / Action to Take
B1 CHECK FOR A SHORT TO GROUND OR A STUCK SWITCH
• Key in ON position. Yes
• Monitor the PCM speed control switch PIDs without pressing any INSTALL a new speed control switch.
speed control switch. REFER to Speed Control Switch in this
• Do any of the PCM PIDs indicate YES? section. CLEAR the DTCs. REPEAT the
self-test.
No
GO to B2.
B2 CHECK CIRCUITS 151 (LB/BK) AND 848 (DG/OG)
• Key in OFF position.
• Disconnect: PCM C175b.
(Continued)

2005 Aviator, 09/2004

310-03-10 Speed Control 310-03-10
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST B: DTC P1566 — SPEED CONTROL COMMAND SWITCHES LOW/OUT OF RANGE
(Continued)
Test Step Result / Action to Take
B2 CHECK CIRCUITS 151 (LB/BK) AND 848 (DG/OG) (Continued)
• Measure the resistance between the PCM C175b-57, circuit 151
(LB/BK), harness side and ground; and between the PCM
C175b-56, circuit 848 (DG/OG), harness side and ground.

Yes
GO to B5.
No
• Are the resistances greater than 10,000 ohms? GO to B3.
B3 CHECK THE HORN SWITCH WIRING HARNESS FOR A SHORT
TO GROUND
• Remove the driver air bag module. Refer to Section 501-20B.
• Disconnect: Horn Switch Wiring Harness Connector.
• Measure the resistance between the PCM C175b-57, circuit 151
(LB/BK), harness side and ground; and between the PCM
C175b-56, circuit 848 (DG/OG), harness side and ground.

Yes
REPAIR or INSTALL a new horn switch
wiring harness. INSTALL the driver air bag
module. Refer to Section 501-20B. CLEAR
the DTCs. REPEAT the self-test.
No
• Are the resistances greater than 10,000 ohms? GO to B4.
B4 CHECK THE CLOCKSPRING
• Disconnect: Clockspring C218a.
(Continued)

2005 Aviator, 09/2004

310-03-11 Speed Control 310-03-11
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST B: DTC P1566 — SPEED CONTROL COMMAND SWITCHES LOW/OUT OF RANGE
(Continued)
Test Step Result / Action to Take
B4 CHECK THE CLOCKSPRING (Continued)
• Measure the resistance between the PCM C175b-57, circuit 151
(LB/BK), harness side and ground; and between the PCM
C175b-56, circuit 848 (DG/OG), harness side and ground.

Yes
INSTALL a new clockspring. REFER to
Section 501-20B. INSTALL the driver air
bag module. Refer to Section 501-20B.
CLEAR the DTCs. REPEAT the self-test.
No
REPAIR the circuit(s) in question.
INSTALL the driver air bag module. Refer
to Section 501-20B. CLEAR the DTCs.
• Are the resistances greater than 10,000 ohms? REPEAT the self-test.
B5 CHECK FOR A SHORT CIRCUIT
• Measure the resistance between the PCM C175b-57, circuit 151
(LB/BK), harness side and the PCM C175b-56, circuit 848
(DG/OG), harness side.

Yes
GO to B9.
No
• Is the resistance greater than 10,000 ohms? GO to B6.
B6 CHECK THE SPEED CONTROL SWITCH
• Remove the driver air bag module. Refer to Section 501-20B.
• Disconnect: Speed Control Switch.
(Continued)

2005 Aviator, 09/2004

310-03-12 Speed Control 310-03-12
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST B: DTC P1566 — SPEED CONTROL COMMAND SWITCHES LOW/OUT OF RANGE
(Continued)
Test Step Result / Action to Take
B6 CHECK THE SPEED CONTROL SWITCH (Continued)
• Measure the resistance between the speed control switch pin 1,
component side and the speed control switch pin 2, component
side.

Yes
GO to B7.
No
INSTALL a new speed control switch.
REFER to Speed Control Switch in this
section. INSTALL the driver air bag
module. Refer to Section 501-20B.
• Is the resistance approximately 4,300 ohms? CLEAR the DTCs. REPEAT the self-test.
B7 CHECK THE HORN SWITCH WIRING HARNESS
• Disconnect: Horn Switch Wiring Harness Connector.
• Measure the resistance between the horn switch wiring harness
connector pin 3, circuit 151, harness side and the horn switch
harness connector pin 2, circuit 848, harness side.

Yes
GO to B8.
No
REPAIR or INSTALL a new horn switch
wiring harness. INSTALL the driver air bag
module. Refer to Section 501-20B. CLEAR
• Is the resistance greater than 10,000 ohms? the DTCs. REPEAT the self-test.
B8 CHECK THE CLOCKSPRING FOR A SHORT
• Measure the resistance between the top of the clockspring pin 2,
component side and the top of the clockspring pin 3, component
side.

Yes
REPAIR circuit 151 (LB/BK) or circuit 848
(DG/OG) as necessary. INSTALL the
driver air bag module. Refer to Section
501-20B. CLEAR the DTCs. REPEAT the
self-test.
No
INSTALL a new clockspring. REFER to
Section 501-20B. INSTALL the driver air
bag module. Refer to Section 501-20B.
• Is the resistance greater than 10,000 ohms? CLEAR the DTCs. REPEAT the self-test.
(Continued)

2005 Aviator, 09/2004

310-03-13 Speed Control 310-03-13
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST B: DTC P1566 — SPEED CONTROL COMMAND SWITCHES LOW/OUT OF RANGE
(Continued)
Test Step Result / Action to Take
B9 CHECK FOR CORRECT PCM OPERATION
• Disconnect all the PCM connectors. Yes
• Check for: INSTALL a new PCM. REFER to Section
• corrosion 303-14. CLEAR the DTCs. REPEAT the
• pushed-out pins self-test.
• Connect all the PCM connectors and make sure they are seated No
correctly. The system is operating correctly at this
• Operate the system and verify the concern is still present. time. The concern may have been caused
• Is the concern still present? by a loose or corroded connector. CLEAR
the DTCs. REPEAT the self-test.

Pinpoint Test C: DTC P1567 — NGSC Driver • circuit 264 (WH/LB) open, short to voltage, or
Fault short to ground
Normal Operation • circuit 265 (LG/WH) open, short to voltage, or
short to ground
Under normal operation, when the powertrain
control module (PCM) senses battery voltage on • circuit 307 (BK/YE) open
circuit 511 (LG) the PCM deactivates the speed • circuit 376 (BN/WH) open, short to voltage, or
control actuator. Additionally, when the brake pedal short to ground
is pressed and the speed control deactivator switch • circuit 1139 (VT/YE) open
opens, battery voltage is removed from circuit 307
(BK/YE) to the speed control actuator and the • PCM
PCM, releasing the throttle independently of the • speed control actuator
speed control actuator. • speed control deactivator switch
Possible Causes
• circuit 133 (BK) open, short to voltage, or short
to ground
PINPOINT TEST C: DTC P1567 — NGSC DRIVER FAULT
Test Step Result / Action to Take
C1 CHECK THE POWERTRAIN CONTROL MODULE (PCM) PIDS
• Test drive the vehicle at greater than 40 km/h (25 mph) with and Yes
without the speed control engaged, while monitoring the PCM If the PCM PID SCINT F indicates YES,
PID SCINT F and SC HW F. GO to C12.
• Does either PCM PID SCINT F or SC HW F indicate If the PCM PID SC HW F indicates
YES? YES, GO to C2.
No
GO to C7.
C2 CHECK CIRCUIT 1139 (VT/YE) FOR AN OPEN
• Key in OFF position.
• Disconnect: Speed Control Actuator C122.
• Key in ON position.
(Continued)

2005 Aviator, 09/2004

310-03-14 Speed Control 310-03-14
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST C: DTC P1567 — NGSC DRIVER FAULT (Continued)
Test Step Result / Action to Take
C2 CHECK CIRCUIT 1139 (VT/YE) FOR AN OPEN (Continued)
• Measure the voltage between the speed control actuator
C122-1, circuit 1139 (VT/YE), harness side and ground.

Yes
GO to C3.
No
REPAIR the circuit. CLEAR the DTCs.
• Is the voltage greater than 10 volts? REPEAT the self-test.
C3 CHECK THE SPEED CONTROL ACTUATOR
• Key in OFF position.
• Measure the resistance between the speed control actuator pins,
component side as follows:

Speed Control Actuator Speed Control Actuator

C122 pin 1 C122 pin 2
C122 pin 1 C122 pin 3
C122 pin 1 C122 pin 4

Yes
GO to C4.
No
INSTALL a new speed control actuator.
REFER to Speed Control Actuator in this
section. CLEAR the DTCs. REPEAT the
• Are the resistances between 2 and 3 ohms? self-test.
C4 CHECK THE SPEED CONTROL ACTUATOR CIRCUITRY FOR A
SHORT TO VOLTAGE
• Disconnect: Powertrain Control Module (PCM) C175b.
• Key in ON position.
• Measure the voltage between the PCM C175b, harness side and
ground as follows:
(Continued)

2005 Aviator, 09/2004

310-03-15 Speed Control 310-03-15
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST C: DTC P1567 — NGSC DRIVER FAULT (Continued)
Test Step Result / Action to Take
C4 CHECK THE SPEED CONTROL ACTUATOR CIRCUITRY FOR A
SHORT TO VOLTAGE (Continued)

Connector — Pin Circuit

C175b-29 264 (WH/LB)
C175b-36 265 (LG/WH)
C175b-46 376 (BN/WH)

Yes
REPAIR the circuit(s) in question. CLEAR
the DTCs. REPEAT the self-test.
No
• Is any voltage present? GO to C5.
C5 CHECK THE SPEED CONTROL ACTUATOR CIRCUITRY FOR
AN OPEN
• Key in OFF position.
• Measure the resistance between the PCM C175b, harness side
and the speed control actuator C122, harness side as follows:

Speed Control
PCM Actuator Circuit
C175b-29 C122-4 264 (WH/LB)
C175b-36 C122-3 265 (LG/WH)
C175b-46 C122-2 376 (BN/WH)

Yes
GO to C6.
No
REPAIR the circuit(s) in question. CLEAR
• Are the resistances less than 5 ohms? the DTCs. REPEAT the self-test.
C6 CHECK THE SPEED CONTROL ACTUATOR CIRCUITRY FOR A
SHORT TO GROUND
• Measure the resistance between the PCM C175b, harness side
and ground as follows:
(Continued)

2005 Aviator, 09/2004

310-03-16 Speed Control 310-03-16
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST C: DTC P1567 — NGSC DRIVER FAULT (Continued)
Test Step Result / Action to Take
C6 CHECK THE SPEED CONTROL ACTUATOR CIRCUITRY FOR A
SHORT TO GROUND (Continued)

PCM Circuit
C175b-29 264 (WH/LB)
C175b-36 265 (LG/WH)
C175b-46 376 (BN/WH)

Yes
REPAIR the circuit(s) in question. CLEAR
the DTCs. REPEAT the self-test.
No
• Are the resistances less than 5 ohms? GO to C7.
C7 CHECK THE SPEED CONTROL DEACTIVATOR SWITCH
CIRCUITRY FOR AN OPEN
• Key in ON position.
• Measure the voltage between the speed control actuator
C122-6, circuit 307 (BK/YE), harness side and ground.

Yes
GO to C8.
No
REPAIR the circuit. CLEAR the DTCs.
• Is the voltage greater than 10 volts? REPEAT the self-test.
(Continued)

2005 Aviator, 09/2004

310-03-17 Speed Control 310-03-17
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST C: DTC P1567 — NGSC DRIVER FAULT (Continued)
Test Step Result / Action to Take
C8 CHECK THE SPEED CONTROL ACTUATOR FOR A SHORT OR
AN OPEN
• Measure the resistance between the speed control actuator pin
5 component side and the speed control actuator pin 6
component side.

Yes
GO to C9.
No
INSTALL a new speed control actuator.
REFER to Speed Control Actuator in this
section. CLEAR the DTCs. REPEAT the
• Is the resistance between 20 and 30 ohms? self-test.
C9 CHECK CIRCUIT 133 (BK) FOR A SHORT TO VOLTAGE
• Key in ON position.
• Measure the voltage between the speed control actuator
C122-5, circuit 133 (BK), harness side and ground.

Yes
REPAIR the circuit. CLEAR the DTCs.
REPEAT the self-test.
No
• Is any voltage present? GO to C10.
C10 CHECK CIRCUIT 133 (BK) FOR AN OPEN
• Key in OFF position.
• Measure the resistance between the speed control actuator
C122-5, circuit 133 (BK), harness side and the PCM C175b-45,
circuit 133 (BK), harness side.

Yes
GO to C11.
No
REPAIR the circuit. CLEAR the DTCs.
• Is the resistance less than 5 ohms? REPEAT the self-test.
(Continued)

2005 Aviator, 09/2004

310-03-18 Speed Control 310-03-18
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST C: DTC P1567 — NGSC DRIVER FAULT (Continued)
Test Step Result / Action to Take
C11 CHECK CIRCUIT 133 (BK) FOR A SHORT TO GROUND
• Measure the resistance between the speed control actuator
C122-5, circuit 133 (BK), harness side and ground.

Yes
GO to C12.
No
REPAIR the circuit. CLEAR the DTCs.
• Is the resistance greater than 10,000 ohms? REPEAT the self-test.
C12 CHECK FOR CORRECT PCM OPERATION
• Disconnect all the PCM connectors. Yes
• Check for: INSTALL a new PCM. REFER to Section
• corrosion 303-14.
• pushed-out pins No
• Connect all the PCM connectors and make sure they are seated The system is operating correctly at this
correctly. time. The concern may have been caused
• Operate the system and verify the concern is still present. by a loose or corroded connector. CLEAR
• Is the concern still present? the DTCs. REPEAT the self-test.

Pinpoint Test D: DTC — P1568 NGSC • circuit 265 (LG/WH) open, short to voltage, or
Actuator Self-Test Failure short to ground
Normal Operation • circuit 376 (BN/WH) open, short to voltage, or
short to ground
Under normal operation the powertrain control
module (PCM) sends signals to the speed control • circuit 307 (BK/YE) open
actuator which receives the signals and adjusts the • circuit 1139 (VT/YE) open
step up motor inside the speed control actuator, • PCM
depending on the various inputs it has received.
• speed control actuator
Possible Causes • speed control deactivator switch
• circuit 133 (BK) open, short to voltage, or short • speed control cable
to ground
• circuit 264 (WH/LB) open, short to voltage, or
short to ground
PINPOINT TEST D: DTC P1568 — NGSC ACTUATOR SELF-TEST FAILURE
Test Step Result / Action to Take
D1 CHECK THE SPEED CONTROL CABLE
• Disconnect the speed control cable at the throttle body. Yes
• Check the speed control cable slack by pulling the speed control GO to D2.
cable end taut from within the speed control cable housing. No
• Is the speed control cable slack greater than 0 mm (0 in) INSTALL a new speed control cable.
and less than 6 mm (0.24 in) ? REFER to Speed Control Cable in this
section. CLEAR the DTCs. REPEAT the
self-test.
(Continued)

2005 Aviator, 09/2004

310-03-19 Speed Control 310-03-19
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST D: DTC P1568 — NGSC ACTUATOR SELF-TEST FAILURE (Continued)
Test Step Result / Action to Take
D2 CHECK FOR A DAMAGED, STICKING, OR BINDING SPEED
CONTROL CABLE
• Disconnect the speed control cable from the speed control Yes
actuator. GO to D3.
• Check the speed control cable for damage, sticking, or binding. No
• Is the speed control cable OK? INSTALL a new speed control cable.
REFER to Speed Control Cable in this
section. CLEAR the DTCs. REPEAT the
self-test.
D3 CHECK THE SPEED CONTROL ACTUATOR OUTPUT
• Key in ON position. Yes
• Check the speed control actuator pulley for movement while GO to D10.
triggering the on-demand self-test. No
• Does the speed control actuator pulley move? GO to D4.
D4 CHECK THE SPEED CONTROL ACTUATOR
• Key in OFF position.
• Disconnect: Speed Control Actuator C122.
• Measure the resistance between the speed control actuator pins,
component side as follows:

Speed Control Speed Control

Actuator Actuator Expected Value
C122 pin 1 C122 pin 2 2 - 3 ohms
C122 pin 1 C122 pin 3 2 - 3 ohms
C122 pin 1 C122 pin 4 2 - 3 ohms
C122 pin 5 C122 pin 6 20 - 30 ohms

Yes
GO to D5.
No
INSTALL a new speed control actuator.
REFER to Speed Control Actuator in this
section. CLEAR the DTCs. REPEAT the
• Are the resistances OK? self-test.
D5 CHECK THE SPEED CONTROL ACTUATOR CIRCUITRY FOR A
SHORT TO VOLTAGE
• Disconnect: Powertrain Control Module (PCM) C175b.
• Key in ON position.
• Measure the voltage between the speed control actuator,
harness side and ground as follows:
(Continued)

2005 Aviator, 09/2004

310-03-20 Speed Control 310-03-20
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST D: DTC P1568 — NGSC ACTUATOR SELF-TEST FAILURE (Continued)
Test Step Result / Action to Take
D5 CHECK THE SPEED CONTROL ACTUATOR CIRCUITRY FOR A
SHORT TO VOLTAGE (Continued)

Speed Control Actuator

Connector — Pin Circuit
C122-5 133 (BK)
C122-4 264 (WH/LB)
C122-3 265 (LG/WH)
C122-2 376 (BN/WH)

Yes
REPAIR the circuit(s)i in question. CLEAR
the DTCs. REPEAT the self-test.
No
• Is any voltage present? GO to D6.
D6 CHECK THE SPEED CONTROL ACTUATOR CIRCUITRY FOR
AN OPEN CIRCUIT
• Key in OFF position.
• Measure the resistance between the PCM, harness side and the
speed control actuator, harness side as follows:

Speed Control
PCM Connector — Actuator
Pin Connector — Pin Circuit
C175b-45 C122-5 133 (BK)
C175b-29 C122-4 264 (WH/LB)
C175b-36 C122-3 265 (LG/WH)
C175b-46 C122-2 376 (BN/WH)

Yes
GO to D7.
No
REPAIR the circuit(s) in question. CLEAR
• Are the resistances less than 5 ohms? the DTCs. REPEAT the self-test.
(Continued)

2005 Aviator, 09/2004

310-03-21 Speed Control 310-03-21
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST D: DTC P1568 — NGSC ACTUATOR SELF-TEST FAILURE (Continued)
Test Step Result / Action to Take
D7 CHECK THE SPEED CONTROL ACTUATOR CIRCUITRY FOR A
SHORT TO GROUND
• Measure the resistance between the PCM, harness side and
ground as follows:

Powertrain Control Module

(PCM) Circuit
C175b-45 133 (BK)
C175b-29 264 (LB/WH)
C175b-36 265 (LG/WH)
C175b-46 376 (BN/WH)

Yes
GO to D8.
No
REPAIR the circuit(s) in question. CLEAR
• Are the resistances greater than 10,000 ohms? the DTCs. REPEAT the self-test.
D8 CHECK CIRCUIT 1139 (VT/YE) FOR AN OPEN
• Key in ON position.
• Measure the voltage between the speed control actuator
C122-1, circuit 1139 (VT/YE), harness side and ground.

Yes
GO to D9.
No
REPAIR the circuit. CLEAR the DTCs.
• Is the voltage greater than 10 volts? REPEAT the self-test.
D9 CHECK THE SPEED CONTROL DEACTIVATOR SWITCH
CIRCUITRY FOR AN OPEN
• Key in OFF position.
(Continued)

2005 Aviator, 09/2004

310-03-22 Speed Control 310-03-22
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST D: DTC P1568 — NGSC ACTUATOR SELF-TEST FAILURE (Continued)
Test Step Result / Action to Take
D9 CHECK THE SPEED CONTROL DEACTIVATOR SWITCH
CIRCUITRY FOR AN OPEN (Continued)
• Measure the voltage between the speed control actuator
C122-6, circuit 307 (BK/YE), harness side and ground.

Yes
INSTALL a new speed control actuator.
REFER to Speed Control Actuator in this
section. CLEAR the DTCs. REPEAT the
self-test.
No
REPAIR the circuit. CLEAR the DTCs.
• Is the voltage greater than 10 volts? REPEAT the self-test.
D10 CHECK FOR CORRECT PCM OPERATION
• Disconnect all the PCM connectors. Yes
• Check for: INSTALL a new PCM. REFER to Section
• corrosion 303-14. CLEAR the DTCs. REPEAT the
• pushed-out pins self-test.
• Connect all the PCM connectors and make sure they are seated No
correctly. The system is operating correctly at this
• Operate the system and verify the concern is still present. time. The concern may have been caused
• Is the concern still present? by a loose or corroded connector. CLEAR
the DTCs. REPEAT the self-test.

Pinpoint Test E: DTC P1572 and DTC P0703 Possible Causes

— Brake ON/OFF Failure and Brake Switch
Input Malfunction • circuit 10 (LG/RD) open
• circuit 307 (BK/YE) open
Normal Operation
• circuit 511 (LG) open
Under normal operation when the brake pedal is
applied, the powertrain control module (PCM) • circuit 1003 (GY/YE) open
receives battery voltage from the stoplamp switch, • speed control deactivator switch
deactivating the speed control system. A speed • PCM
control deactivator switch opens when the brake is
• speed control actuator
firmly applied, deactivating the speed control.
PINPOINT TEST E: DTC P1572 AND DTC P0703 — BRAKE ON/OFF FAILURE AND BRAKE SWITCH
INPUT MALFUNCTION
Test Step Result / Action to Take
E1 MONITOR THE POWERTRAIN CONTROL MODULE (PCM) PID
BPA SW
• Key in ON position. Yes
• Monitor the PCM PID BPA SW without applying the brake GO to E2.
pedal. No
• Does the PCM BPA SW PID indicate ON? GO to E5.
E2 CHECK FOR AN OPEN CIRCUIT
• Key in OFF position.
• Disconnect: Powertrain Control Module (PCM) C175b.
• Key in ON position.
(Continued)

2005 Aviator, 09/2004

310-03-23 Speed Control 310-03-23
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST E: DTC P1572 AND DTC P0703 — BRAKE ON/OFF FAILURE AND BRAKE SWITCH
INPUT MALFUNCTION (Continued)
Test Step Result / Action to Take
E2 CHECK FOR AN OPEN CIRCUIT (Continued)
• Measure the voltage between the PCM C175b-28, circuit 307
(BK/YE), harness side and ground.

Yes
GO to E6.
No
• Is the voltage greater than 10 volts? GO to E3.
E3 CHECK THE SPEED CONTROL DEACTIVATOR SWITCH
• Key in OFF position.
• Disconnect: Speed Control Deactivator Switch C2227.
• Connect a fused (5A) jumper wire between the speed control
deactivator switch C2227-1, circuit 307 (BK/YE), harness side
and the speed control deactivator switch C2227-2, circuit 10
(LG/RD), harness side.

• Key in ON position.
• Measure the voltage between the PCM C175b-28, circuit 307
(BK/YE), harness side and ground.

Yes
INSTALL a new speed control deactivator
switch. REFER to Speed Control
Deactivator Switch in this section.
No
• Is the voltage greater than 10 volts? REMOVE the jumper wire. GO to E4.
(Continued)

2005 Aviator, 09/2004

310-03-24 Speed Control 310-03-24
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST E: DTC P1572 AND DTC P0703 — BRAKE ON/OFF FAILURE AND BRAKE SWITCH
INPUT MALFUNCTION (Continued)
Test Step Result / Action to Take
E4 CHECK CIRCUIT 307 (BK/YE) FOR AN OPEN
• Key in OFF position.
• Measure the resistance between the PCM C175b-28, circuit 307
(BK/YE), harness side and the speed control deactivator switch
C2227-1, circuit 307 (BK/YE), harness side.

Yes
REPAIR circuit 10 (LG/RD) or 1003
(GY/YE) as necessary. CLEAR the DTCs.
REPEAT the self-test.
No
REPAIR circuit 307 (BK/YE). CLEAR the
• Is the resistance less than 5 ohms? DTCs. REPEAT the self-test.
E5 CHECK THE BRAKE PEDAL POSITION (BPP) INPUT TO THE
PCM
• Key in OFF position.
• Disconnect: PCM C175b.
• Key in ON position.
• Measure the voltage between the PCM C175b-40, circuit 511
(LG), harness side and ground while applying the brake pedal.

Yes
GO to E6.
No
REPAIR the circuit. CLEAR the DTCs.
• Is the voltage greater than 10 volts? REPEAT the self-test.
E6 CHECK FOR CORRECT PCM OPERATION
• Key in OFF position.
• Disconnect all the PCM connectors. Yes
• Check for: INSTALL a new PCM. REFER to Section
• corrosion 303-14.
• pushed-out pins No
• Connect all the PCM connectors and make sure they are seated The system is operating correctly at this
correctly. time. The concern may have been caused
• Operate the system and verify the concern is still present. by a loose or corroded connector. CLEAR
• Is the concern still present? the DTCs. REPEAT the self-test.

2005 Aviator, 09/2004

310-03-25 Speed Control 310-03-25
DIAGNOSIS AND TESTING (Continued)
Pinpoint Test F: The Speed Control Is Possible Causes
Inoperative — No DTCs
• circuit 1144 (YE/BK) open or short to ground
Normal Operation • speed control switch
Under normal operation the digital transmission • speed control deactivator switch
range (TR) sensor enables the speed control
• BPP
switches to send signals to the powertrain control
module (PCM) inputs for the speed control system. • PCM
The PCM interprets the signals and outputs them to • digital TR sensor
the speed control actuator. The step-up motor in the
speed control actuator then pulls the cable to the
correct position enabling the speed control to be set.
When the brake pedal is pressed the brake pedal
position (BPP) switch and the speed control
deactivator switch will in turn deactivate the speed
control system.
PINPOINT TEST F: THE SPEED CONTROL IS INOPERATIVE — NO DTCs
Test Step Result / Action to Take
F1 CHECK THE POWERTRAIN CONTROL MODULE (PCM) PID
IDBRKSW
• Key in ON position. Yes
• Monitor the PCM PID IDBRKSW. GO to F3.
• Does the PCM PID IDBRKSW indicate OFF? No
GO to F2.
F2 CHECK THE STOPLAMP SWITCH INPUT TO THE PCM
• Key in OFF position.
• Disconnect: PCM C175b.
• Measure the voltage between the PCM C175b-40, circuit 511
(LG), harness side and ground.

Yes
REFER to Section 417-01 to continue
diagnosis of the stoplamps.
No
• Is any voltage present? GO to F8.
F3 CHECK THE PCM PID BPA SW
• Monitor the PCM PID BPA SW while firmly applying the brake Yes
pedal. GO to F4.
• Does the PCM PID BPA SW indicate ON with the brake No
pedal firmly applied? INSTALL a new speed control deactivator
switch. REFER to Speed Control
Deactivator Switch in this section.
F4 CHECK THE DIGITAL TRANSMISSION RANGE (TR) SENSOR
• Key in OFF position.
• Disconnect: Digital TR Sensor C167.
(Continued)

2005 Aviator, 09/2004

310-03-26 Speed Control 310-03-26
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST F: THE SPEED CONTROL IS INOPERATIVE — NO DTCs (Continued)
Test Step Result / Action to Take
F4 CHECK THE DIGITAL TRANSMISSION RANGE (TR) SENSOR
(Continued)
• Measure the resistance between the digital TR sensor C167 pin
2 component side, and the digital TR sensor C167 pin 4
component side while placing the transmission range selector
lever in PARK and DRIVE.

Yes
GO to F5.
No
• Is the resistance less than 5 ohms when the selector is in INSTALL a new digital TR sensor. REFER
PARK and greater than 10,000 ohms when the selector is in to Section 307-01. TEST the system for
DRIVE ? normal operation.
F5 CHECK CIRCUIT 1144 (YE/BK) FOR A SHORT TO GROUND
• Disconnect: Powertrain Control Module (PCM) C175t.
• Measure the resistance between the digital TR sensor C167-4,
circuit 1144 (YE/BK), harness side and the PCM C175t-22,
circuit 1144 (YE/BK), harness side; and between the digital TR
sensor C167-4, circuit 1144 (YE/BK), harness side and ground.

Yes
• Is the resistance less than 5 ohms between the digital TR GO to F6.
sensor and the PCM, and greater than 10,000 ohms between No
the digital TR sensor and ground? REPAIR the circuit. REPEAT the self-test.
(Continued)

2005 Aviator, 09/2004

310-03-27 Speed Control 310-03-27
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST F: THE SPEED CONTROL IS INOPERATIVE — NO DTCs (Continued)
Test Step Result / Action to Take
F6 CHECK CIRCUIT 359 (GY/RD) FOR AN OPEN AND A SHORT TO
GROUND
• Measure the resistance between the digital TR sensor C167-2,
circuit 359 (GY/RD), harness side and the PCM C175t-17, circuit
359 (GY/RD), harness side; and between the digital TR sensor
C167-2, circuit 359 (GY/RD), harness side and ground.

Yes
• Is the resistance less than 5 ohms between the digital TR GO to F7.
sensor and the PCM, and greater than 10,000 ohms between No
the digital TR sensor and ground? REPAIR the circuit. REPEAT the self-test.
F7 CHECK THE PCM SPEED CONTROL SWITCH PID
• Key in ON position. Yes
• Monitor the PCM speed control switch PID while pressing and GO to F8.
releasing the speed control switches. No
• Does the speed control switch match the PCM PID? INSTALL a new speed control switch.
REFER to Speed Control Switch in this
section. CLEAR the DTCs. REPEAT the
self-test.
F8 CHECK THE PCM PID VBAT
• Monitor the PCM PID VBAT. Yes
• Does the PCM PID VBAT indicate greater than 10 volts with GO to F9.
the engine running? No
REFER to Section 414-00 to continue
diagnosis of the charging system..
F9 CHECK FOR CORRECT PCM OPERATION
• Disconnect all the PCM connectors. Yes
• Check for: INSTALL a new PCM. REFER to Section
• corrosion 303-14. CLEAR the DTCs. REPEAT the
• pushed-out pins self-test.
• Connect all the PCM connectors and make sure they are seated No
correctly. The system is operating correctly at this
• Operate the system and verify the concern is still present. time. The concern may have been caused
• Is the concern still present? by a loose or corroded connector. CLEAR
the DTCs. REPEAT the self-test.

Pinpoint Test G: The Speed Control Possible Causes

Indicator Lamp Is Always On
• PCM
Normal Operation • instrument cluster
Under normal operation the instrument cluster
receives a signal from the powertrain control
module (PCM) to indicate that the speed control
system is activated.

2005 Aviator, 09/2004

310-03-28 Speed Control 310-03-28
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST G: THE SPEED CONTROL INDICATOR LAMP IS ALWAYS ON
Test Step Result / Action to Take
G1 CHECK THE POWERTRAIN CONTROL MODULE (PCM)
• Key in OFF position. Yes
• Disconnect all the PCM connectors. GO to G2.
• Key in ON position. No
• Is the concern still present? GO to G3.
G2 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
• Key in OFF position.
• Disconnect all the instrument cluster connectors. Yes
• Check for: INSTALL a new instrument cluster.
• corrosion REFER to Section 413-01. TEST the
• pushed-out pins system for normal operation.
• Connect all the instrument cluster connectors and make sure No
they are seated correctly. The system is operating correctly at this
• Operate the system and verify the concern is still present. time. The concern may have been caused
• Is the concern still present? by a loose or corroded connector.
G3 CHECK FOR CORRECT PCM OPERATION
• Key in OFF position.
• Disconnect all the PCM connectors. Yes
• Check for: INSTALL a new PCM. REFER to Section
• corrosion 303-14. TEST the system for normal
• pushed-out pins operation.
• Connect all the PCM connectors and make sure they are seated No
correctly. The system is operating correctly at this
• Operate the system and verify the concern is still present. time. The concern may have been caused
• Is the concern still present? by a loose or corroded connector.

2005 Aviator, 09/2004

310-03-1 Speed Control 310-03-1

REMOVAL AND INSTALLATION

Speed Control Cable

Item Part Number Description 2. Disconnect the speed control cable from the
1 W704425 Engine appearance cover nuts throttle lever.
(2 required)
3. Disconnect the speed control cable from the
2 9E766 Engine appearance cover
speed control cable bracket.
3 9A825 Speed control cable (throttle
lever end)
4. Disconnect the speed control cable from the
4 9C736 Speed control cable bracket speed control actuator and remove.
5 9A825 Speed control cable (actuator
end) 5. To install, reverse the removal procedure.
6 9A825 Speed control cable • Make sure the tabs on the speed control
cable are locked in place and cable is fully
Removal and Installation seated in the accelerator bracket.
• Make sure the rubber seal is fully seated
1. Remove the 2 nuts and the engine appearance
onto the speed control cable cap.
cover

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
310-03-1 Speed Control 310-03-1

REMOVAL AND INSTALLATION

Speed Control Actuator

Item Part Number Description 2. Disconnect the speed control actuator electrical
1 9A825 Speed control cable actuator connector.
end
3. Remove the 2 bolts and the speed control
2 14398 Speed control actuator
electrical connector actuator and bracket assembly.
3 W701928-S424 Speed control actuator bracket • To install, tighten to 12 Nm (9 lb-ft).
to body bolts (2 required)
4 9C736 Speed control actuator bracket 4. To install, reverse the removal procedure.
5 W701928-S424 Speed control actuator to Make sure the tabs on the speed control cable
bracket bolts (3 required) are locked in place and cable is fully seated in
6 9C735 Speed control actuator accelerator bracket.
• Make sure the rubber seal is fully seated
Removal and Installation onto the speed control cable cap.

1. Disconnect the speed control cable from the

speed control actuator.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
310-03-1 Speed Control 310-03-1

REMOVAL AND INSTALLATION

Speed Control Switch

Item Part Number Description 2. Remove the 4 bolts and springs and position the
1 — Horn switch plate bolts and horn switch plate aside.
screws (4 required)
3. NOTE: Note the routing of the steering wheel
2 — Horn switch plate
controls harness on the module plate for
3 — Steering wheel controls installation of the new steering wheel controls.
screws (4 required)
4 14K147 Steering wheel control Disconnect the steering wheel controls switch
switches harness from the clips and remove the horn
switch plate.
Removal and Installation
4. Remove the 4 screws and the steering wheel
controls switches.
1. Remove the driver air bag module. For
additional information, refer to Section
5. To install, reverse the removal procedure.
501-20B.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
310-03-1 Speed Control 310-03-1

REMOVAL AND INSTALLATION

Speed Control Deactivator Switch Installation

NOTE: When installing the speed control

deactivator switch it is automatically self-adjusting
to the proper position. Do not pull up or push down
on the pedal during installation. Initial installation of
the speed control deactivator switch allows for one
adjustment. If additional adjustments are necessary,
install a new switch.

1. Install the speed control deactivator switch, and

rotate clockwise 45 degrees.

Item Part Number Description

1 14A005 Speed control deactivator
switch electrical connector
2 9F924 Speed control deactivator
switch

Removal

CAUTION: Do not press the pedal when

removing or installing the speed control
deactivator switch, as the switch will be
damaged.

1. Disconnect the speed control deactivator switch

electrical connector.

2. Rotate counterclockwise 45 degrees and remove

the speed control deactivator switch.

Copyright  2004, Ford Motor Company

Last updated: 10/7/2004 2005 Aviator, 09/2004
310-03-2 Speed Control 310-03-2
REMOVAL AND INSTALLATION (Continued)
2. Connect the speed control deactivator switch
electrical connectors.

2005 Aviator, 09/2004