A/C - Intermittent Loss of Cooling at Highway Speeds

Article No.
04-5-9

03/22/04

CLIMATE CONTROL - INTERMITTENT LOSS OF
COOLING OR AIRFLOW FROM A/C SYSTEM AT
HIGHWAY DRIVES - VEHICLES BUILT PRIOR TO
3/16/2004

FORD:
2003-2004 EXPEDITION

LINCOLN:
2003-2004 NAVIGATOR

ISSUE
Some 2003-2004 Expedition/Navigator vehicles built before 03/16/2004 may exhibit an intermittent loss of cooling (temperature swings) or diminished register airflow from the A/C system during highway drives. Diminished airflow on drives of 30 minutes or more may be due to ice formation on the evaporator core. This condition is exhibited in hot and humid climates only. Temperature swings with strong register airflow may be due to unwanted cycling of the thermostatic switch. This condition occurs only when the rear climate control system is not present or turned off.

ACTION
To service, install an evaporator assembly-mounted thermostatic cycling switch and disable the TXV-mounted thermostatic switch, using service Kit 4L1Z-19E992-AA. For vehicles built on or after August 2003, it is also necessary to order and install fastener W701696-S301. For installation procedures refer to the Service Kit instruction sheet.

NOTE
TOOLS REQUIRED FOR PROCEDURE INCLUDE A 1/2" DRILL BIT AND A 1/2" STOP COLLAR FOR THE DRILL BIT. A SUITABLE STOP COLLAR IS CONTAINED IN MAC TOOL KIT GN5838. USE OF A STOP COLLAR IS MANDATORY TO PREVENT DAMAGE TO THE EVAPORATOR CORE.





Parts Block

OTHER APPLICABLE ARTICLES: NONE

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

OPERATION DESCRIPTION TIME

040509A Navigator: Install 1.5 Hrs.
Evaporator Assembly
Mounted Thermostatic
Cycling Switch And
Harness

040509B Expedition: Install 1.8 Hrs.
Evaporator Assembly
Mounted Thermostatic
Cycling Switch And
Harness (Includes Time To
Remove And Install Center
Console)

DEALER CODING
CONDITION
BASIC PART NO. CODE
19C734 42





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