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Removal and Installation

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 airbag module. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: If a seat equipped with a SRS component is being serviced, the SRS must be depowered. 
NOTE: The air bag warning lamp illuminates when the 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: The backrest thermo-electric device (TED) filter is detachable from the TED assembly housing and can be replaced without TED removal.

    All seats 

  1. Remove the front seat and depower the supplemental restraint system (SRS). For additional information, refer to SEAT - FRONT .
  2. Remove the front seat backrest. For additional information, refer to SEAT BACKREST - FRONT .

    3. Seat with side air bag 

  3. Detach the side air bag bolt cover.
    4. NOTE: Note the position of the side air bag module locator hook in the side air bag module bracket (on the seat back frame) for installation.
  4. Remove the bolt and lift up and out to detach the side air bag module from the seat backrest.
    • To install, tighten to 10 Nm (89 lb-in).
  5. Slide and disengage the side air bag module electrical connector locking clip, and then release the tab and disconnect the side air bag module electrical connector and remove the side air bag module.

    6. All seats 

  6. Detach the 2 pin-type retainers and trim cover flaps from the recliners.
    Fig 1: Locating Pin-Type Retainers
    G04683497Courtesy of FORD MOTOR CO.
    7. CAUTION: Use care when separating the seat back trim cover from the hook and loop strip, or the hook and loop strip can be torn from the backrest foam pad.
    Fig 2: Locating Outer And Inner Backrest Trim Cover Lower J-Clips
    G04683498Courtesy of FORD MOTOR CO.
  7. Release the 2 outer and inner backrest trim cover lower J-clips and partially invert the trim cover to the hook and loop strips.
    8. NOTE: The head restraint guides are not interchangeable. Note location for installation.
    Fig 3: Removing Head Restraint Guides From Backrest Frame
    G04683499Courtesy of FORD MOTOR CO.
  8. Reach up into the backrest and squeeze the head restraint guide ends together to release. Pull the 2 head restraint guides out of the backrest frame.
    9. CAUTION: Use care when separating the seat back trim cover from the hook and loop strip, or the hook and loop strip can be torn from the backrest foam pad.
  9. Separate the hook and loop strips and invert the trim cover up the backrest to the rear upper hog rings.
  10. Remove the rear upper hog rings and trim cover.
    11. CAUTION: Inspect the climate controlled seat backrest manifold for crush and obstruction before installation. If damaged, install a new backrest manifold.
  11. If necessary, remove the climate controlled seat backrest manifold from the foam pad.
    • To install, align the backrest manifold and insert into the valleys of the foam pad.
      • Check for correct fit between the manifold, foam pad and thermo-electric device (TED) assembly, to make sure there is no air flow obstruction or cushion crush.
  12. Remove the hog rings from the upper support spring and remove the foam pad.
    Fig 4: Locating Hog Rings
    G04683500Courtesy of FORD MOTOR CO.
  13. Disconnect the backrest TED assembly electrical connector and detach the wiring harness retainers.
    Fig 5: Locating Backrest TED Assembly Electrical Connector And Wiring Harness Retainer
    G04683501Courtesy of FORD MOTOR CO.
  14. Remove the TED exhaust duct.
    • Cut and remove the tie strap.
      • During installation, install a new tie strap.
    • Remove the pin-type retainer and separate the exhaust duct from the TED.
  15. Disconnect the backrest upper support spring from the backrest frame and remove the spring support with the TED attached.
  16. If necessary, detach the backrest TED filter from the TED.
    17. NOTE: Note the TED position on the support spring for installation.
  17. Use an appropriate tool and separate the TED from the upper backrest support spring.
    18. CAUTION: Cover the TED openings before removing any rivets to prevent debris from entering the TED.
  18. Remove the 3 rivets and bracket from the TED.
    19. WARNING: 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.
    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.
    NOTE: A backrest trim cover for a seat with a side air bag module is different than a backrest trim cover for a seat without a side air bag module. Make sure the correct backrest trim cover is being installed.
  19. To install, reverse the removal procedure.
  20. Install the backrest trim cover. For additional information, refer to SEAT BACKREST COVER - FRONT .
  21. Install the front seat backrest. For additional information, refer to SEAT BACKREST - FRONT .
  22. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time.  For additional information, refer to SEAT - FRONT .

    23. Passenger seat 

  23. Carry out the OCCUPANT CLASSIFICATION SENSOR (OCS) SYSTEM ZERO SEAT WEIGHT TEST and prove out the SRS.
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