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Passenger Air Bag Module - Zephyr: Removal

WARNING: This page is about a different car, the 2006 Mercury Milan, 2006 Lincoln Zephyr, and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
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.
WARNING: Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: 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.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged deployment doors must be replaced, not repainted.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again.
  1. Depower the system. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING .
  2. Open the glove compartment door and release the door dampener cable, then fully lower the door.
    Fig 1: Locating Door Dampener Cable
    G04684052Courtesy of FORD MOTOR CO.
  3. Remove the instrument panel (I/P) end panel.
    4. NOTE: Illustration shows the location of the 5 RH I/P trim panel nuts located inside of the I/P.
    Fig 2: Locating RH I/P Trim Panel Nuts
    G04684053Courtesy of FORD MOTOR CO.
  4. Through the glove compartment opening and the side of the I/P, remove the 5 RH I/P trim panel nuts on the inside the I/P.
  5. Pull out on the RH I/P trim panel releasing the 2 clips, then remove the RH I/P trim panel.
  6. Through the glove compartment opening, remove the 2 passenger air bag module bolts.
    7. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door.
  7. Through the glove compartment opening, release the deployment door clips from the I/P and then remove the passenger air bag module from the I/P.
    8. NOTE: RH side shown, LH similar.
    Fig 3: Locating Passenger Air Bag Module Electrical Connectors
    G04684054Courtesy of FORD MOTOR CO.
  8. Using a small screwdriver as shown, lift up and release the locking buttons on the passenger air bag module electrical connectors.
    9. CAUTION: Do not pull the passenger air bag module electrical connectors out by the locking buttons. Damage to the locking buttons can occur.
    NOTE: RH side shown, LH similar.
    Fig 4: Locating Passenger Air Bag Module Electrical Connectors
    G04684055Courtesy of FORD MOTOR CO.
  9. With the locking buttons released, remove the electrical connectors and the passenger air bag module.
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