Attachment III - Technical Information
SERVICE PROCEDURE1. Record radio stations, then disconnect battery negative cable.
2. Remove steering column lower opening panel (knee bolster).
3. Remove four (4) junction block assembly retaining bolts/nuts. See Figure 1.
4. Disconnect junction block electrical connectors.
5. Disconnect GEM electrical connectors.
6. Remove junction block assembly.
7. Check engineering suffix of the GEM part number (-14B205-), shown in Figure 2. Vehicles without Remote Keyless Entry (RKE) Replace GEM if the part number suffix is any designation other than "DJ" Vehicles with Remote keyless Entry (RKE) Replace GEM if the part number suffix is any designation other than "EL".
8. Remove GEM-to-junction block retaining screws. Refer to Figure 3.
9. Using flat bladed screwdriver, separate GEM from junction block.See Figure 3. There will be some resistance when removing the GEM, due to an electrical connector between the two units.
10. Attach new GEM to junction block. Make sure electrical connector is fully seated. See Figure 4.
11. Install GEM-to-junction block retaining screws. Tighten screws to 2-3 Nm (18-26 lb-in).
12. Position junction block assembly in vehicle.
13. Connect two (2) GEM electrical connectors.
14. Connect two (2) junction block electrical connectors. Tighten retaining screws to 5-6 Nm (44-53 lb-in).
15. Install four (4) junction block assembly retaining bolts/nuts. Tighten retaining screws to 5-6 Nm (44-53 lb-in).
16. Install steering column lower opening panel (knee bolster).
17. Connect battery negative cable.
18. On vehicles equipped with manual transmission, proceed as follows:
Reconfigure GEM for manual transmission as follows:
- Obtain Ford Service Function (FSF) Program card with software level of 4.0 or higher.
- Insert FSF Program Card into NGS.
- Connect NGS into the DLC.
- Turn ignition switch to Run position (engine off).
- Scroll highlighted bar to "SERVICE BAY FUNCTIONS," then press trigger button.
- Scroll highlighted bar to "GEM - GENERIC ELECTRONIC MODULE," then press trigger button.
- Scroll highlighted bar to "MANUFACTURE OPTIONS," then press trigger button.
^ If the NGS displays: "-COMMUNICATION LINK ESTABLISHED - YOU MUST MAKE SELECTION FOR THE FOLLOWING FIELD: VEHICLE," press trigger button.
- Scroll highlighted bar to "TRANSMISSION," then press trigger button.
- Turn dial to the right and "ENABLED" will change to "DISABLED." Press trigger button.
- Press DONE (numeric 8 button) and the GEM module will be programmed to a manual transmission equipped vehicle.
Disconnect NGS from DLC.
Remove FSF Program Card from NGS.
Insert Diagnostic Card into NGS.
Connect NGS to DLC.
Retrieve and clear all Diagnostic Trouble Codes (DTC).
Retrieve DTC's again.
If there are no DTC's, proceed to Step 19. If ABS codes B2141 and/or B2477 are present, reconfigure the ABS module for correct tire/axle ratio as follows:
- Disconnect NGS from DLC.
- Remove Diagnostic Card from NGS.
- Insert same Ford Service Function (FSF) Program card (software level of 4.0 or higher) into NGS.
- Connect NGS into the DLC.
- Turn ignition switch to Run position (engine off).
- Scroll highlighted bar to "SERVICE BAY FUNCTIONS," then press trigger button.
- Scroll highlighted bar to "ABS -ANTI LOCK BRAKE MODULE," then press trigger button.
- Scroll highlighted bar to "TIRE SIZE/AXLE RATIO CONFIGURE," then press trigger button.
^ If the NGS displays: "-COMMUNICATION LINK ESTABLISHED - YOU MUST MAKE SELECTION FOR THE FOLLOWING FIELD: VEHICLE," press trigger button.
Scroll highlighted bar to "TIRE SIZE," then press trigger button.
- Turn dial to the right until correct tire size is displayed, then press trigger button.
- If tire size is not listed, rotate dial until "-- REVS/MILE" is displayed, then press trigger button. Use the following formula to calculate revolutions per mile:
^ 63360 divided by circumference of tire measured in inches. Add 2 zeros in front of the solution.
Enter this number into the NGS, then press trigger button.
- Scroll highlighted bar to "TONE RING SIZE." Verify 10.50 IN/27CM (00120) is displayed.
- Scroll highlighted bar to "OPTION," then press trigger button.
- Turn dial to the right until "N/A" is displayed. Press trigger button.
- Scroll highlighted bar to "VEHICLE," then press trigger button.
- Turn dial to the right until "F2501F350" is displayed. Press trigger button.
- Press DONE (numeric 8 button) and the ABS module will be reconfigured.
- Remove NGS from DLC.
- Recheck speedometer accuracy.
19. On vehicles equipped with keyless entry, reprogram remote transmitters as follows:
Turn the ignition from OFF to RUN five (5) times within ten (10) seconds, ending in RUN. If the GEM has successfully entered program mode, it will lock and unlock all the doors.
Press a button on remote transmitter, wait several seconds. The doors should lock and unlock. Repeat this step for all remote transmitters.
Turn the ignition switch to the OFF position. If the GEM has exited program mode, it will lock and unlock all the doors one last time.
20. Program radio stations.