2010 ford flex service repair manual

service repair manual download

1. 2009 ACCESSORIES & BODY, CAB
Instrument Panel and Console - Flex
SPECIFICATIONS
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION AND OPERATION
REFRIGERATOR
The rear floor console may be equipped with a refrigerator feature. The refrigerator operates only when the
ignition is in the ON position. The refrigerator should only be used when the engine is running. If there is a
need to use the unit when the engine is off, limit the time the refrigerator is running to avoid draining the
battery.
If the refrigerator is active and the ignition is turned to the OFF position, the refrigerator will also turn off. The
last known state of the refrigerator will be stored into the refrigerator module memory. When the ignition is
turned back to the ON position, the refrigerator/freezer will automatically activate to the last known state that is
stored in the refrigerator module memory.
The refrigerator/freezer is equipped with the following:
Refrigerator switch (located on rear floor console)
Compressor/motor assembly (not serviceable)
Refrigerant (not serviceable)
Refri
gerator module (not serviceable)
Description Nmlb-ftlb-in
Front floor console lower bolts 6 - 53
Front floor console rear lower bolts 6 - 53
Ground wire bolts 10 - 89
Instrument panel center support bracket bolts 2518 -
Instrument panel side bolts 4030 -
Instrument panel upper cowl bolts 2518 -
PCM nuts 5 - 44
Passenger side air bag-to-cross beam bolts 9 - 80
Rear floor console bolts 7 - 62
Steering column shaft-to-steering column bolt 2518 -
Strut upper mount nuts 3022 -
Thermostatic Expansion Valve (TXV) manifold bolt 8 - 71

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex
Microsoft
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2. Cool Mode
To activate the refrigerator, depress the refrigerator switch to the COOL position for approximately 1 second
until the COOL LED illuminates. When the refrigerator is in cool mode, the temperature will cool to
approximately 41°F (5°C). In order to turn the refrigerator off when the refrigerator is in cool mode, depress the
refrigerator switch to the COOL position for approximately 1 second, until the COOL LED turns off. When the
refrigerator is in the cool mode, the refrigerator can be switched to freeze mode by depressing the refrigerator
switch to the FREEZE position for approximately 1 second, until the COOL LED turns off and the FREEZE
LED illuminates.
Freeze Mode
To activate the freezer, depress the refrigerator switch to the FREEZE position for approximately 1 second,
until the FREEZE LED illuminates. When the refrigerator is in freeze mode, the temperature will cool to
approximately 23°F (-5°C). In order to turn the freezer off when the refrigerator is in freezer mode, depress the
refrigerator switch to the FREEZE position for approximately 1 second, until the FREEZE LED turns off. When
the refrigerator is in the freeze mode, the refrigerator can be switched to cool mode by depressing the
refrigerator switch to the COOL position for approximately 1 second, until the FREEZE LED turns off and the
COOL LED illuminates.
Diagnostic Mode
In the event of a system concern, the refrigerator is equipped with the capabilities to provide self diagnostics.
For information on the diagnostic mode, refer to the Principles of Operation located in REFRIGERATOR
.
DIAGNOSIS AND TESTING
REFRIGERATOR
Special Tool(s)
SPECIAL TOOL REFERENCE CHART
73III Automotive Meter
105-R0057 or equivalent

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3. Principles of Operation
Refrigerator
The refrigerator consists of a switch, module and motor assembly, which contains a cooling fan, refrigerant, a
condenser and a compressor. The refrigerator relay, located in the Battery Junction Box (BJB), controls voltage
to the refrigerator. The refrigerator relay coil is grounded at all times. When the ignition switch is in the RUN or
ACCESSORY position, voltage is supplied to the refrigerator relay coil from Smart Junction Box (SJB) fuse 34
(5A) and the relay closes. When the refrigerator relay is closed, voltage is sent to the refrigerator from BJBfuse
15 (15A).
The temperature of the refrigerator is controlled by a sensor located in the refrigerator module. When a
refrigerator mode is selected and the refrigerator temperature is above the target temperature, the compressor
will activate. If the temperature is below the target temperature, there is no need for cooling and the compressor
will stop. The compressor start up has a predetermined time delay to avoid a potential rapid changing
compressor on and off situation.
The heat from the compressor and condenser is pushed out of the vents of the refrigerator by means of a fan.
This fan runs continuously, as soon as a refrigerator mode is selected. The fan will not stop with the compressor
if the target temperature is reached.
Diagnostic Mode
The refrigerator can be switched into a diagnostic mode to read the potential error codes of the compressor.
When the refrigerator is in diagnostic mode, the COOL LED on the refrigerator switch will flash 1-5 times,

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4. depending on the error. Perform the following steps in order to access the refrigerator diagnostic mode:
1. Turn the ignition switch to the ON position.
2. Depress the refrigerator switch to the FREEZE position for approximately 1 second, until the FREEZE
LED illuminates.
3. Depress the refrigerator switch again to the FREEZE position for approximately 5 seconds, until the
FREEZE LED flashes quickly and repeatedly.
4.
When the FREEZE LED is quickly flashing, the COOL LED will display the error code by flashing 1-5
times, depending on the error.
5.
To turn the diagnostic mode off, depress the refrigerator switch to the FREEZE position for approximately 1
second. The FREEZE LED will stop flashing, but it will remain illuminated and the refrigerator will be in
freeze mode.
DIAGNOSTIC ERROR CODE DESCRIPTION CHART
Inspection and Verification
1. Verif
y the customer concern.
NOTE: Use the Diagnostic Mode Error Co de Chart to determine the error.
NOTE: If the refrigerator is in diagnostic mode and the ignition is turned OFF, the
refrigerator will restart in FREEZE mode when the ignition is turned back
to the ON position.
Number
of Flashes
Diagnostic
Error Code
Diagnostic Error Code Description
1
Battery protection
cutout
The voltage level at the refrigerator 12 volt connector is below the parameter
settings. This code may set when the refrigerator has been active with the
engine off.
2
Fan over-
current cut-out
The fan loads the electronic unit with more than 1 amp peak. Refer to INSPECTION AND VERIFICATION
.
3
Motor start
error
The rotor is blocked or the differential pressure in the unit is too high. This
may occur in high ambient temperature situations or if the refrigerator was
stopped and restarted within a short period at a high load and/or a high
ambient temperature condition. Let the differential pressure lower, before
attempting to restart the refrigerator.
4
Minimum
motor speed
error
The refrigeration system is so heavily loaded by ambient temperatures that the
motor cannot maintain a minimum speed of 1,850 rpm. Let the refrigerator
system cool down before attempting to restart the refrigerator.
5
Thermal cut-
out of
electrical unit
The refrigerator is so heavily loaded by ambient temperatures that the
refrigerator module gets too hot. Check the vents and the area of the
compressor, condenser for a blockage, possibly from dust. Check the fan for
correct operation.

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5. 2. Visually inspect for obvious signs of mechanical or electrical damage:
VISUAL INSPECTION CHART
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.
4. If the concern is not visually evident, verify the symptom and GO to SYMPTOM CHART .
Symptom Chart
SYMPTOM CHART
Pinpoint Tests
Pinpoint Test A: The Refrigerator Does Not Operate Correctly
Refer to SYSTEM WIRING DIAGRAMS , Refrigerated Console for schematic and connector information.
Normal Operation
When the ignition switch is in the RUN or ACCESSORY position, voltage is supplied to the refrigerator relay
coil from Smart Junction Box (SJB) fuse 34 (5A), through circuit CBP34 (VT/BN). The refrigerator relay coil is
grounded at all times through circuit GD120 (BK/GN). High current voltage is supplied to the refrigerator relay
from Battery Junction Box (BJB) fuse 15 (15A), through circuit SBB15 (WH/RD). When the refrigerator relay
is activated, voltage is supplied to the refrigerator through circuit CBB15 (BN/BU). The refrigerator is
grounded through circuit GD149 (BK/GY).
This pinpoint test is intended to diagnose the following:
Mechanical Electrical
Refrigerator
Battery Junction Box (BJB) fuse 15 (15A)
Smart Junction Box (SJB) fuse 34 (5A)
Refrigerator
Refrigerator relay
Refrigerator switch
Loose or corroded connections
Wiring harness
Condition Possible Sources Action
The refrigerator does not operate
correctly
Fuse(s)
Refrigerator relay
Refrigerator switch
Refrigerator
Circuitry
Go To PINPOINT TEST
A.

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6. Fuse(s)
Refrigerator relay
Refrigerator switch
Refrigerator
Wiring, terminals or connectors
PINPOINT TEST A: THE REFRIGERATOR DOES NOT OPERATE CORRECTLY
A1 CHECK CIRCUIT CBB15 (BN/BU) FOR VOLTAGE
Disconnect: Refrigerator C3415.
Ignition ON.
Measure the voltage between refrigerator C3415-1, circuit CBB15 (BN/BU), harness side and
ground.
Fig. 1: Measuring Voltage Between Refrigerator C3415-1, Circuit CBB15 (BN/BU), Harness
Side And Ground
Courtesy of FORD MOTOR CO.
Is the voltage greater than 10 volts?
Yes : GO to A6.
No : GO to A2.
A2 CHECK THE REFRIGERATOR RELAY
Ignition OFF.
Disconnect: Refrigerator Relay.
Carry out the Relay component test for the BJB refrigerator relay.
Refer to SYSTEM WIRING DIAGRAMS
for component testing.
Did the refrigerator relay pass the component test?
Yes : GO to A3.
No : INSTALL a new refrigerator relay. TEST the system for normal operation.
A3 CHECK CIRCUIT CBP34 (VT/BN) FOR VOLTAGE
I
gnition ON.

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7. Measure the voltage between BJB refrigerator relay pin 1, circuit CBP34 (VT/BN), harness side
and ground.
Fig. 2: Measuring Voltage Between BJB Refrigerator Relay Pin 1, Circuit CBP34 (VT/BN),
Harness Side And Ground
Courtesy of FORD MOTOR CO.
Is the voltage greater than 10 volts?
Yes : GO to A4.
No : VERIFY SJB fuse 34 (5A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the
appropriate SystemWiring Diagrams to identify the possible causes of the circuit short. TEST the
system for normal operation.
A4 CHECK CIRCUIT SBB15 (WH/RD) FOR VOLTAGE
Measure the voltage between BJB refrigerator relay pin 3, circuit SBB15 (WH/RD), harness side
and
ground.

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8. Fig. 3: Measuring Voltage Between BJB Refrigerator Relay Pin 3, Circuit SBB15 (WH/RD),
Harness Side And Ground
Courtesy of FORD MOTOR CO.
Is the voltage greater than 10 volts?
Yes : GO to A5.
No : VERIFY BJB fuse 15 (15A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the
appropriate System Wiring Diagrams to identify the possible causes of the circuit short. TEST the
system for normal operation.
A5 CHECK FRONT WIPER RELAY CI RCUIT GD120 (BK/GN) FOR GROUND
Measure the resistance between BJBrefri
gerator relay pin 2, circuit GD120 (BK/GN) and ground.

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9. Fig. 4: Measuring Resistance Between BJB Refrigerator Relay Pin 2, Circuit GD120 (BK/GN)
And Ground
Courtesy of FORD MOTOR CO.
Is the resistance less than 5 ohms?
Yes : REPAIR open in circuit CBB15 (BN/BU). TEST the system for normal operation.
No : REPAIR open in circuit GD120 (BK/GN). TEST the system for normal operation.
A6 CHECK CIRCUIT GD149 (BK/GY) FOR AN OPEN
Ignition OFF.
Measure the resistance between refrigerator C3415-3, circuit GD149 (BK/GY), harness side and
ground.
Fig. 5: Measuring Resistance Between Refrigerator C3415
-3, Circuit GD149 (BK/GY),
Harness Side And Ground
Courtesy of FORD MOTOR CO.

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10. Is the resistance less than 5 ohms?
Yes : GO to A7.
No : REPAIR the circuit(s). TEST the system for normal operation.
A7 CHECK THE REFRIGERATOR SWITCH
Remove the refrigerator switch. Refer to REFRIGERATOR SWITCH
.
Carry out the Refrigerator Switch Component Test.
Did the refrigerator switch pass the component test?
Yes : GO to A8.
No : INSTALL a new refrigerator switch.
A8 CHECK FOR CORRECT REFRIGERATOR OPERATION
Disconnect all refrigerator connectors.
Check for:
corrosion.
pushed-out pins.
Connect all the refrigerator connectors and make sure they seat correctly.
Operate the system and verify the concern is still present.
Is the concern still present?
Yes : INSTALL a new refrigerated rear floor console. REFER to CONSOLE
- REAR, FLOOR.
No : The system is operating correctly at this time. Concern may have been caused by a loose or
corroded connector. TEST the system for normal operation.
Component Test
Refrigerator Switch
Fig. 6: Identifying Refrigerator Switch

Courtesy of FORD MOTOR CO.
REFRIGERATOR SWITCH REFERENCE CHART
Connect Self-Powered Test Light or Ohmmeter to
Terminals
Move Switch to this
Position
A Good Switch will
Indicate
1 and 2 COOL Closed

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11. REMOVAL AND INSTALLATION
INSTRUMENT PANEL - EXPLODED VIEW
Instrument Panel Finish Panels and Fasteners
1 and 3 - Open
1 and 4 - Open
1 and 5 - Open
1 and 6 FREEZE Closed
2 and 3 - Open
2 and 4 - Open
2 and 5 - Open
2 and 6 - Open
3 and 4 - Open
3 and 5 - Open
3 and 6 - Open
4 and 5 - Open
4 and 6 - Open
5 and 6 - Open

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12. Fig. 7: Exploded View Of Instrument Panel With Torque Specifications
Courtesy of FORD MOTOR CO.
WINDOW MOULDING - REAR QUARTER
Instrument Panel Trim Panels, Finish Panels and Electrical Connectors
Item Part Number Description
1W709178 Instrument panel upper cowl bolt (3 required)
204480 RH/ 04481 LHInstrument panel side trim panel
3W712210 Instrument panel side finish panel retaining clip (5 required per side)
4W712961 Steering column shaft-to-steering column bolt
5W710259 Instrument panel side bolt (6 required)
6W709268 Instrument panel center support bracket bolt (4 required)

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13. Fig. 8: Identifying Instrument Panel Trim Panels, Finish Panels And Electrical Connectors
Courtesy of FORD MOTOR CO.
WINDOW MOULDING - REAR QUARTER
ItemPart Number Description
1 N808453 Steering column opening trim panel screw (3 required)
2 04459 Steering column opening trim panel
3 W712210 Steering column opening trim panel retaining clip (3 required)
4 - LH instrument panel electrical connector (part of 14401)
5 - Lower LH instrument panel electrical connectors (part of 14401)
6 - Small RCM electrical connector (part of 14401)
7 - RH instrument panel electrical connector (part of 14401)
8 18812A Antenna cable
9 04338 RH Instrument panel finish panel

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14. Instrument Panel and Instrument Cluster Finish Panels
Fig. 9: Identifying Instrument Panel And Instrument Cluster Finish Panels
Courtesy of FORD MOTOR CO.
REMOVAL AND INSTALLATION
Instrument Panel Upper Section
10W712210 RH Instrument panel finish panel retaining clip (8 required)
1104339 LH Instrument panel finish panel
12W712210 LH Instrument panel finish panel retaining clip (2 required)
ItemPart Number Description
1 W707628 Center instrument panel finish panel screw (6 required)
2 04302 Center instrument panel finish panel
3 W712210 Center instrument panel finish panel retaining clip (7 required)
4 - Instrument cluster finish panel screw covers (part of 044D70)
5 W707628 Instrument cluster finish panel screw (3 required)
6 044D70 Instrument cluster finish panel
7 W712210 Instrument cluster finish panel retaining clip (3 required)
8 13A018 Light sensor
9 - Light sensor electrical connector (part of 14401)
10044E82 Instrument panel defroster grille
11W712210 Instrument panel defroster grille retaining clip (14 required)

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15. Fig. 10: Identifying Instrument Panel Upper Section
Courtesy of FORD MOTOR CO.
TIGHTENING TORQUE SPECIFICATIONS
1. For additional information, refer to the appropriate procedures.
INSTRUMENT PANEL
Removal
1. Rotate the steering wheel until the front wheels are in the straight-ahead position.
2. Drain the coolant. For additional information, refer to ENGINE COOLING
.
3. Recover the refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM -
GENERAL INFORMATION AND DIAGNOSTICS .
4. Remove the wiper mounting arm and pivot shaft assembly. For additional information, refer to WIPERS
AND WASHERS .
5. Disconnect the 3 PCM electrical connectors.
Item Part Number Description
1 W505424 Hood release handle bolt
2 16916 Hood release handle
3 W707628 Instrument panel upper section screw (13 required)
4 04320 Instrument panel upper section
5 04545 In-vehicle crossbeam

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16. 6. Remove the wire harness retainer from the PCM bracket stud.
Fig. 11: Locating Wire Harness Retainer Of PCM Bracket Stud
Courtesy of FORD MOTOR CO.
7. Remove the 2 nuts and the PCM.
Fig. 12: Locating PCM Nuts
Courtesy of FORD MOTOR CO.
8. Remove the 3 nuts and the PCM bracket.
Fig. 13: Locating PCM Bracket Nuts
Courtesy of FORD MOTOR CO.
9. Remove the vacuum hose clip from the strut tower cross brace.

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17. Fig. 14: Locating Vacuum Hose Clip
Courtesy of FORD MOTOR CO.
10.
Remove the strut tower cross brace.
Remove the LH and RH strut upper mount inboard nuts.
Fig. 15: Locating Strut Upper Mount Inboard Nuts

Courtesy of FORD MOTOR CO.
11. Remove the vacuum hose and the evaporator purge solenoid hose from the upper intake manifold and
position aside.
Fig. 16: Locating Vacuum Hose And Evaporator Purge Solenoid Hose
NOTE: LH side shown in illu stration, RH side similar.

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2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex
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18. Courtesy of FORD MOTOR CO.
12. Remove the crankcase vent tube and the vacuum tube from the Air Cleaner (ACL) outlet pipe.
Fig. 17: Locating Crankcase Vent Tube And Vacuum Tube
Courtesy of FORD MOTOR CO.
13. Loosen the ACL outlet pipe-to-Throttle Body (TB) clamp and the ACL outlet pipe-to- ACLcover clamp.
Fig. 18: Locating ACL Outlet Pipe-To-Throttle Body Clamp And ACL Outlet Pipe-To-ACL Cover
Clamp
Courtesy of FORD MOTOR CO.
14. Remove the ACL outlet pipe.
15. Remove the heater hoses from the heater hose separator.
Fig. 19: Locating Heater Hoses

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19. Courtesy of FORD MOTOR CO.
16. Remove the heater hoses from the heater hose tubes and position aside.
Fig. 20: Locating Heater Hoses Clamp
Courtesy of FORD MOTOR CO.
17. Remove the heater hoses from the heater core and position aside.
Fig. 21: Locating Heater Hoses Clamp
Courtesy of FORD MOTOR CO.
18. Remove the Thermostatic Expansion Valve (TXV) manifold bolt and the TXV manifold.
Discard the O-ring seals.
Fig. 22: Locating Thermostatic Expansion Valve Manifold Bolt

Courtesy of FORD MOTOR CO.

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20. 19. Remove the RH and LH instrument panel upper cowl bolts.
20. Remove the steering wheel. For additional information, refer to STEERING COLUMN .
21. Remove the front seats. For additional information, refer to SEATING .
22. Remove the front floor console. For additional information, refer to CONSOLE - FRONT, FLOOR.
23. Remove the LH and RH front door scuff plate trim panels.
Lift the scuff plate trim panels upward to release the retaining clips.
24. Remove the LH and RH front door opening weatherstrips.
25. Remove the LH and RH A-pillar trim panels. For additional information, refer to INTERIOR TRIM
AND ORNAMENTATION .
26. Remove the LH and RH instrument panel side trim panels.
Pull the instrument panel side trim panels outward to release the retaining clips.
27. Remove the LH and RH lower cowl trim panels.
Pull the lower cowl trim panels rearward to release the retaining clips.
28. Remove the hood release handle bolt and position aside the hood release handle.
Fig. 23: Locating Hood Release Handle Bolt

Courtesy of FORD MOTOR CO.
29. Disconnect the LH instrument panel bulkhead electrical connector.
Fig. 24: Locating LH Instrument Panel Bulkhead Electrical Connector
Courtesy of FORD MOTOR CO.
30. Disconnect the 2 Smart Junction Box (SJB) lower electrical connectors and the lower bulkhead electrical

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21. connector.
Fig. 25: Locating Smart Junction Box Lower Electrical Connectors And Lower Bulkhead Electrical
Connector
Courtesy of FORD MOTOR CO.
31. Remove and discard the steering column shaft-to-steering column bolt.
Fig. 26: Locating Steering Column Shaft-To-Steering Column Bolt
Courtesy of FORD MOTOR CO.
32. Detach the steering column shaft from the steering column.
33. Remove the driver footrest pad.
Remove the 2 pin-type retainers.
Fig. 27: Locating Pin
-Type Retainers

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2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex
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