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Dashboard / instrument panel: service and repair removal and installation note: removal and installation of the instrument panel is best accomplished by two people. Wiring and circuit protection for routing and connection locations. Removal and installation 1. Position front wheels in the straight ahead position. 2. Disconnect positive battery cable. 3. Remove cluster finish panel, please refer to body and frame/interior trim/dash board/service and repair/ see: 4. 5. 6. 7. Disconnect all electrical connections from steering column switches. Remove two bolts and reinforcement from under steering column. Disengage insulator retainer and remove insulator. Remove four nuts and absorber assembly from under steering column. Caution: do not rotate steering column shaft. 8. Disconnect park brake release cable and wiring connector from park brake and ignition switch wiring connector. 9. Remove four nuts retaining steering column to support, disconnect prndl cable (column shift) and lower column on front seat. Cover front seat to protect from damage. 10. Install lock cylinder to ensure that steering column shaft does not turn.

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Issue some 2006-2007 fusion/milan, 2006 zephyr and 2007 mkz equipped with electronic manual temperature control (emtc), dual automatic temperature control (datc) and/or electronic automatic temperature control (eatc) systems may exhibit an intermittent blower motor operation or a blower motor that may shift to and remain at high speed. In certain intermittent conditions, cycling the ignition or running the blower motor on high speed for one minute may help to return it to normal blower motor operation. Action follow the service procedure steps to correct the condition. Service procedure 1. Check the blower motor bar code numbers on the vehicle. Note the blower motor bar codes numbers are below the bar code. (figure 1)

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Issue some vehicles with high-current aftermarket devices (such as motors for wheel chair lifts) operating at 75 amps or higher may cause electrical transients (voltage spikes), leading to damage of the airbag electronic crash sensor (ecs) module. If this occurs, the airbag lamp will turn on indicating a fault in the airbag system and diagnostic trouble codes (dtc) b1876, b1880, b1915 and/or b1920 will be present. Action follow normal diagnostics per workshop manual, section 501-20b. If pinpoint tests lead to replacement of the ecs module, and the vehicle does contain high-current aftermarket equipment, installation of an ecs module circuit protection improvement kit is recommended. This will prevent recurring damage to the new ecs module.

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Service procedure note: do not remove the dash or the dash insulator at any time during this procedure. Water leak testing procedure 1. To pressurize the cabin open trunk and remove the floor carpet. Remove the plastic tail panel cover. Remove side carpet push pins and move the carpet aside. Locate the body vents in the lower rear corners of the trunk (rear of wheel wells) and tape them off. Close the trunk. Place the blower motor on high. Turn air recirculation to off mode. Close windows and doors. Open the hood and spray soapy water along body seams / grommets, particularly around the a-pillar / fender and hood hinge area, and check for bubbles. Note: 2. Using a garden hose equipped with a shower head attachment, or similar device, run water onto the vehicle being sure to direct water over the roof ditch moldings, side window weather strips, and windshield / cowl panel area. While water is being applied to the vehicle, have an assistant inside the vehicle verifying the location of the water intrusion. Water leak inspection / repair procedure inspect the following areas for visible signs of leaks and follow the appropriate repair steps. 1. Verify that the plastic cowl panel grill is evenly seated against the windshield and not warped. If warped, replace with current service stock. 2. Remove the cowl panel grill. Refer to workshop manual (wsm), section 501-02, and inspect for proper cowl panel mount grommet installation and pinch weld sealing. Water may enter the cowl channel, through the cowl panel grommets / seals or forward pinch weld, potentially causing a sloshing sound and/or water leaking down the dash kick panel area. If there is standing water in the cowl channel, remove by siphoning through a cowl panel mount grommet hole. (figures 7-8 – end of article) 3. Verify that the ten (10) cowl panel mount grommets and seals are installed and sealing tightly to the vehicle. If any are missing, or the seals are damaged, replace as necessary. (figure 1) figure 1 – article 08-26-7 a. Remove old cowl grommets and clean entire cowl surface with a suitable wax and grease remover. If silicone and/or seam sealer was used to seal grommets, ensure all sealer is removed before installing new grommets. B. With surface clean and prepped, snap the hot melt cowl grommet into cowl panel. C. Using a suitable heat gun, heat the hot melt cowl grommet until the hot melt material begins to squeeze out from under the plastic grommet. Do not over heat the grommet because deformation of the plastic grommet may occur. D. After heating the grommets, a light amount of pressure may be applied to the outer perimeter of the grommet to help sealing. E. Do not over heat around windshield or fender edges or damage may result.