Front Seat Backrest Captain's Chair

DISASSEMBLY

WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ ANYTIME THE SIDE AIR BAG HAS DEPLOYED, THE SEAT BACKREST FRAME MUST BE REPLACED. DO NOT ATTEMPT TO REPAIR THE SEAT BACKREST FRAME OR SIDE AIR BAG MOUNTING BRACKET. THE SEAT BACKREST FRAME MUST BE INSTALLED NEW. FAILURE TO DO SO MAY CAUSE THE SIDE AIR BAG MODULE TO NOT FUNCTION CORRECTLY, POSSIBLY RESULTING IN PERSONAL INJURY.
^ INSPECT THE SIDE AIR BAG MODULE MOUNTING BRACKET FOR DAMAGE. IF THE MOUNTING BRACKET IS DAMAGED DO NOT ATTEMPT TO REPAIR THE SEAT BACKREST FRAME OR SIDE AIR BAG MODULE MOUNTING BRACKET. IF DAMAGED, THE SEAT BACKREST FRAME MUST BE INSTALLED NEW. FAILURE TO DO SO MAY CAUSE THE SIDE AIR BAG MODULE TO NOT FUNCTION CORRECTLY, POSSIBLY RESULTING IN PERSONAL INJURY.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL /RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.

NOTE:
^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems.
^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle.
^ Diagnostics may be performed on seat Systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle.
^ Seat backrest with power lumbar shown, seat backrest with manual lumbar is similar.
^ Navigator is shown, Expedition is similar.

1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems.
2. Remove the seat backrest from the seat bottom. For additional information, refer to Front Seat Backrest-Captain's Chair with Side Air Bag.







3. Remove the head restraint.
^ Insert an appropriate tool into the hole of the head restraint guide to release the rod on both sides.







4. Cut the zip-ties at the bottom of the seat backrest frame, releasing the inlet and exhaust climate control ducts (if equipped).

NOTE: Left duct is shown, right duct is similar.







5. Remove the Thermo-Electric Device (TED) and ducts (if equipped).
1 Remove the TED wire harness pin-type retainers from the duct.
2 Cut the zip-ties and remove the ducts.
3 Cut the zip-tie and remove the TED.







6. Squeeze the head restraint guides together where indicated and pull them out of the seat backrest frame.







7. Separate the side air bag module wire harness pin-type retainers from the seat backrest frame and remove the harness from the frame.

NOTE: If the pin-type retainers are damaged, install new retainers. This will keep the wire harness routed correctly.







8. Remove the side air bag plastic shield.







9. Remove the side air bag module retaining nuts.

NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module nuts.







10. Position the side air bag module and deployment chute away from the mounting bracket and seat backrest frame.
^ Route the side air bag module wire harness out from the seat backrest frame.







11. Remove the seat backrest frame from the trim cover and foam pad.







12. Remove the side air bag module from the deployment chute.
^ Pull the side air bag module mounting studs back through the deployment chute openings and remove the side air bag module from the deployment chute.







13. Disconnect the side air bag module.
1 Slide the side air bag electrical connector locking clip to disengage it.
2 Release the two connector tabs by pushing in on them and disconnect the side air bag module.
3 Remove the side air bag module.







14. Separate the seat backrest trim cover from the pad.
^ Carefully separate the hook and loop strip.

CAUTION: Use care when separating the seat backrest pad trim cover from the hook and loop strip, or the hook and loop strip can be torn from the seat backrest pad.

NOTE: Front seat backrest trim covers installed on seats with side air bags cannot be repaired. New front seat backrest trim covers are to be installed (cleaning is permissible).







15. Remove the lumbar support.
1 Flex the lumbar support.
2 Separate the lumbar support adjusting cable from the positioning spring.
3 Release the clips.
4 Remove the lumbar support.







16. Remove the power lumber support motor.
1 Disconnect and remove the power lumbar electrical connector and harness.
2 Remove the screws.
3 Remove the power lumbar support motor.

ASSEMBLY

WARNING:
^ FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR BAGS CANNOT BE REPAIRED; THEY ARE TO BE REPLACED (CLEANING IS PERMISSIBLE).
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ ANYTIME THE SIDE AIR BAG HAS DEPLOYED, THE SEAT BACKREST FRAME MUST BE REPLACED. DO NOT ATTEMPT TO REPAIR THE SEAT BACKREST FRAME OR SIDE AIR BAG MOUNTING BRACKET. THE SEAT BACKREST FRAME MUST BE INSTALLED NEW. FAILURE TO DO SO MAY CAUSE THE SIDE AIR BAG MODULE TO NOT FUNCTION CORRECTLY, POSSIBLY RESULTING IN PERSONAL INJURY.
^ INSPECT THE SIDE AIR BAG MODULE MOUNTING BRACKET FOR DAMAGE. IF THE MOUNTING BRACKET IS DAMAGED DO NOT ATTEMPT TO REPAIR THE SEAT BACKREST FRAME OR SIDE AIR BAG MODULE MOUNTING BRACKET. IF DAMAGED, THE SEAT BACKREST FRAME MUST BE INSTALLED NEW. FAILURE TO DO SO MAY CAUSE THE SIDE AIR BAG MODULE TO NOT FUNCTION CORRECTLY, POSSIBLY RESULTING IN PERSONAL INJURY.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED).







1. Install the power lumbar support motor.
1 Position the power lumbar support motor and install the screws.
2 Connect and route the power lumbar electrical connector and harness.







2. Install the lumbar support.
1 Position the lumbar support to the seat backrest frame.
2 Align the retaining clips and seat them in the holes.
3 Hook the lumbar support adjusting cable to the lumbar support.
4 Flex the lumbar support.
5 Insert the lumbar support adjusting cable to the positioning spring.







3. Position the seat backrest pad into the trim cover.
^ Push the trim cover hook and loop strip into the channel of the seat pad.

NOTE: Front seat backrest trim covers installed on seats with side air bags cannot be repaired. New front seat backrest trim covers are to be installed (cleaning is permissible).







4. Connect the side air bag module electrical connector.
1 Install the connector to the side air bag module.
2 Slide the side air bag module electrical connector locking clip to secure the connector to the side air bag module.
5. Make sure the electrical connector is securely fastened to the side air bag module.







6. Position the side air bag module into the deployment chute.
^ Position the side air bag module into the deployment chute with the alignment pin offset to the top and the electrical connector to the bottom of the seat back. This will position the alignment pin correctly when the side air bag module and deployment chute are mounted to the seat back frame mounting bracket.

WARNING:
^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ BEFORE INSTALLING THE SIDE AIR BAG MODULE INTO THE DEPLOYMENT CHUTE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE FOR DAMAGE. THE DEPLOYMENT CHUTE MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE, THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT.
^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY.

NOTE:
^ The alignment pin will only allow the side air bag module to be installed to the seat back mounting bracket one way.







7. Position the side air bag module in the deployment chute.
1 The side air bag module mounting studs must come through the deployment chute stud openings.
2 Wrap the remaining deployment chute flap around the side air bag module.







8. Make sure the side air bag module mounting studs come through the deployment chute flap stud openings.







9. Position the seat backrest frame to the trim cover and foam pad.
^ Route the side air bag wire harness to the back side of the seat backrest frame.

WARNING:
^ ANYTIME THE SIDE AIR BAG HAS DEPLOYED, THE SEAT BACKREST FRAME MUST BE REPLACED. DO NOT ATTEMPT TO REPAIR THE SEAT BACKREST FRAME OR SIDE AIR BAG MOUNTING BRACKET. THE SEAT BACKREST FRAME MUST BE INSTALLED NEW. FAILURE TO DO SO MAY CAUSE THE SIDE AIR BAG MODULE TO NOT FUNCTION CORRECTLY, POSSIBLY RESULTING IN PERSONAL INJURY.
^ INSPECT THE SIDE AIR BAG MODULE MOUNTING BRACKET FOR DAMAGE. IF THE MOUNTING BRACKET IS DAMAGED DO NOT ATTEMPT TO REPAIR THE SEAT BACKREST FRAME OR SIDE AIR BAG MODULE MOUNTING BRACKET. IF DAMAGED, THE SEAT BACKREST FRAME MUST BE INSTALLED NEW. FAILURE TO DO SO MAY CAUSE THE SIDE AIR BAG MODULE TO NOT FUNCTION CORRECTLY, POSSIBLY RESULTING IN PERSONAL INJURY.







10. Install the side air bag module and deployment chute onto the front seat backrest frame mounting bracket.
^ The deployment chute should not have any wrinkles or folds where it contacts the seat backrest frame mounting bracket.
^ Tighten the retaining nuts to specification.

WARNING: INSPECT THE MOUNTING SURFACES OF THE DEPLOYMENT CHUTE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS, BEFORE INSTALLING THE SIDE AIR BAG MODULE/DEPLOYMENT CHUTE ASSEMBLY. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT.







11. Install the side air bag plastic shield.







12. Route the side air bag module wire harness and install the pin-type retainers to the seat backrest frame.

NOTE: If the pin-type retainers are damaged, install new retainers. This will keep the side air bag wire harness routed correctly.







13. Install the TED and ducts (if equipped).
1 Position the TED and zip-tie it to the seat backrest frame.
2 Install the ducts to the TED and zip-tie them in place.
3 Route the TED wire harness and install the pin-type retainers into the duct.

NOTE: When installing the upper TED, make sure the snorkel is positioned into the seat backrest pad opening.







14. Position the inlet and exhaust climate control ducts and zip-tie them in place to the bottom of the seat backrest frame (if equipped).

NOTE: Left duct is shown, right duct is similar.







15. Position the seat backrest trim cover openings at the top and install the head restraint guides.







16. Install the head restraint.
17. Install the seat backrest to the seat bottom. For additional information, refer to Front Seat Backrest-Captain's Chair with Side Air Bag.

18. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems.

WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.

19. If equipped, prove out the air bag system. For additional information, refer to Air Bag Systems.
20. Check the restraint system for correct operation.