1997-2004 Ford F-250 / F-350 Service & Repair Manual

AIR BAG RESTRAINT SYSTEM (F150 & F250 LD) 1997 ACCESSORIES/SAFETY EQUIPMENT Ford Motor Co. - Air Bag Restraint System IDENTIFICATION Vehicle is equipped with driver-side air bag which is identified by a letter "L" in fourth position of Vehicle Identification Number (VIN). VIN is located on top of instrument panel, near lower left corner of windshield. VIN is also stamped on Vehicle Certification (VC) label, mounted on left front door pillar. The words Supplemental Restraint System (SRS) are embossed on steering wheel center hub. A label denoting that vehicle is equipped with air bag is affixed to driver-side sun visor. DESCRIPTION & OPERATION The Supplemental Restraint System (SRS) is designed to provide increased accident protection for driver and passenger by deploying air bags in a front-end collision. The air bags, stored in center of steering wheel and in instrument panel above glove box, deploy in about 40 milliseconds after impact sensors close. SRS is designed to be used with 3-point safety belts. During a front-end collision of sufficient force, both a front impact sensor and a safing sensor will activate simultaneously to inflate air bag. When a front impact sensor and safing sensor are closed at same time, electrical current will flow, igniting the driver-side and passenger-side air bag module. SRS includes following components: diagnostic monitor, driver-side air bag module, passenger-side air bag module and deactivation switch, SRS readiness light (AIR BAG warning light), front impact sensor and safing sensor, ignitor assemblies (in air bag modules), clockspring and associated wiring harnesses. See Fig. 1 . WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all WARNINGS and SERVICE PRECAUTIONS . 1997 Ford Pickup F350 AIR BAG RESTRAINT SYSTEM (F150 & F250 LD) 1997 ACCESSORIES/SAFETY EQUIPMENT Ford Motor Co. - Air Bag Restraint System 1997 Ford Pickup F350 AIR BAG RESTRAINT SYSTEM (F150 & F250 LD) 1997 ACCESSORIES/SAFETY EQUIPMENT Ford Motor Co. - Air Bag Restraint System

Fig. 1: Locating SRS Components Courtesy of FORD MOTOR CO. 1997 Ford Pickup F350 AIR BAG RESTRAINT SYSTEM (F150 & F250 LD) 1997 ACCESSORIES/SAFETY EQUIPMENT Ford Motor Co. - Air Bag Restraint System

BACK-UP POWER SUPPLY A back-up power supply is used on all models and is located inside diagnostic monitor. If battery or battery cables are damaged in a collision before front impact sensors close circuit, back-up power supply will deploy air bag. Back-up power supply will hold a deployment charge for approximately one minute after positive battery cable is disconnected. CLOCKSPRING The steering column contains a clockspring to transfer electrical signals from steering column wiring harness to driver-side air bag module. Clockspring is mounted to steering column behind steering wheel. DIAGNOSTIC MONITOR The diagnostic monitor (located on left side of steering column underneath instrument panel) contains a microcomputer, which monitors electrical system components and connections. Diagnostic monitor performs a system self-check of SRS internal circuits every time ignition switch is turned to RUN position. Monitor also energizes SRS readiness indicator light (AIR BAG warning light) during initial system self-check and whenever a fault is detected. Faults are translated into flash codes and are displayed through AIR BAG warning light. If a system fault exists and/or AIR BAG warning light is malfunctioning, an audible tone will sound, indicating need for service. See TONE GENERATOR . Diagnostic monitor can also disarm SRS if certain faults occur. The air bag diagnostic monitor does not deploy air bags in the event of a collision. The right or left front impact sensors and safing sensor determine air bag deployment. The safing sensor is internal to air bag diagnostic monitor and is not replaced separately. DRIVER-SIDE AIR BAG MODULE The driver-side air bag module is mounted on center of steering wheel, covered by steering wheel trim cover. When a front impact sensor and safing sensor close, signaling an impact, ignitor triggers inflator. During ignition, sodium azide reacts with copper oxide, producing nitrogen gas, which inflates air bag. When air bag deploys, tear-seams molded into steering wheel trim cover separate, allowing inflation of air bag assembly. Driver-side air bag module is not serviceable and must be replaced as a complete assembly. PASSENGER-SIDE AIR BAG MODULE The passenger-side air bag module is mounted in right side of instrument panel, above glove box. When a front impact sensor and safing sensor close, signaling an impact, air bag igniters trigger inflator. Since passenger-side air bag is larger than driver-side air bag, inflator contains more gas generant in a different configuration to produce more gas. When air bag is activated, instrument panel trim cover tears at seams and hinges, allowing inflation. Passenger-side air bag module is only serviced as a complete assembly. PASSENGER-SIDE AIR BAG DEACTIVATION SWITCH 1997 Ford Pickup F350 AIR BAG RESTRAINT SYSTEM (F150 & F250 LD) 1997 ACCESSORIES/SAFETY EQUIPMENT Ford Motor Co. - Air Bag Restraint System

The Passenger-side Air bag Deactivation (PAD) switch is located on center instrument panel, below climate control vent, and contains a light diode (LED) that indicates when PAD switch is activated. This switch allows the passenger-side air bag deployment circuit to be disabled by inserting ignition key into PAD switch lock cylinder and turning key. It should be used whenever child safety seat is being used in front passenger-side seating position. ELECTRICAL SYSTEM SRS is powered directly from battery and can function with ignition switch in any position, including OFF and LOCK. System can also function when driver-side seat is unoccupied. The 3 main functions performed by electrical subsystem are: detecting an impact, switching electric power to igniters for air bag, and monitoring readiness of SRS. FRONT IMPACT SENSORS Front impact sensors are located at right and left sides of radiator support. Each impact sensor reacts to impacts according to direction and force. It discriminates between impacts that require air bag inflation and impacts that do not. When an impact occurs requiring air bag inflation, impact sensor contacts close, completing electrical circuit necessary for system operation. At least 2 sensors, safing sensor and one front impact sensor, must be activated simultaneously to inflate air bag. TONE GENERATOR AIR BAG warning light is prime means of determining SRS condition; however, a series of 5 audible tones, indicating that system requires servicing, will sound if AIR BAG warning light is out, and a fault occurs in system. Unless serviced, SRS may not function properly in an accident. Tone generator is located within diagnostic monitor. SYSTEM OPERATION CHECK 1. When checking SRS operation, and upon completion of each diagnostic test, check for faults in SRS. To check system, turn ignition switch to RUN position. If AIR BAG warning light illuminates for 4-8 seconds and then goes out, SRS is functioning properly and no fault codes exist. 2. If a fault code is detected in SRS during initial system check, AIR BAG warning light will either fail to light, stay on continuously, or flash a code sequence. If AIR BAG warning light flashes, indicating a fault in system, count number of flashes after fault code has cycled twice. Number of flashes represents a code number used to diagnose SRS. See DIAGNOSIS & TESTING . 3. If a system fault exists and AIR BAG warning light fails to light, an audible tone will be heard, indicating AIR BAG warning light is out and service is required. See TONE GENERATOR under DESCRIPTION & OPERATION. SERVICE PRECAUTIONS These precautions should be observed when working with SRS: 1997 Ford Pickup F350 AIR BAG RESTRAINT SYSTEM (F150 & F250 LD) 1997 ACCESSORIES/SAFETY EQUIPMENT Ford Motor Co. - Air Bag Restraint System

 Disable SRS before servicing any SRS or steering column components. Failure to do so may result in accidental air bag deployment and personal injury. See procedures under DISABLING & ACTIVATING AIR BAG SYSTEM .  Wait one minute after disabling SRS before working on vehicle. Back-up power supply holds a deployment charge for approximately one minute after positive battery cable is disconnected. Servicing SRS before one minute may cause accidental air bag deployment and possible personal injury.  Because of critical system operating requirements, DO NOT service impact sensors, clockspring, diagnostic monitor or air bag module. Repairs are made by replacement only.  Always wear safety glasses whenever servicing an air bag equipped vehicle or handling an air bag.  When carrying a live air bag module, ensure air bag module and trim cover are pointed away from your body. This minimizes chance of injury in event of an accidental deployment.  When placing a live air bag module on a bench or other surface, always face air bag module and trim cover facing up and away from surface. This will reduce motion of module if it is accidentally deployed.  After deployment, air bag surface may contain deposits of sodium hydroxide, which may irritate skin. Sodium hydroxide is a product of gas generant combustion. Always wear gloves and safety glasses when handling a deployed air bag. Wash your hands using mild soap and water. Follow correct disposal procedures. See DISPOSAL PROCEDURES .  If scrapping a vehicle with an undeployed air bag module, air bag must be deployed. See DISPOSAL PROCEDURES .  If a part is replaced and new part does not correct condition, reinstall original part and perform diagnostic procedure again.  Never probe connectors on air bag module. Doing so may cause air bag deployment and/or personal injury.  Instruction to disconnect always refers to connector. DO NOT remove component from vehicle if instructed to disconnect.  After any servicing, ensure AIR BAG warning light does not indicate any fault codes. See SYSTEM OPERATION CHECK .  Replace air bag module if trim cover (deployment doors) is marred or damaged. DO NOT repaint trim cover. Paint may degrade cover material. Replace air bag module as necessary. See PROCEDURE 1 under SCRAPPED VEHICLE under DISPOSAL PROCEDURES. DISABLING & ACTIVATING AIR BAG SYSTEM WARNING: Wait one minute after disabling SRS before working on vehicle. Back-up power supply holds a deployment charge for approximately one minute after positive battery cable is disconnected. Servicing SRS before one minute may cause accidental air bag deployment and possible personal injury. CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES in GENERAL INFORMATION before DISCONNECTING 1997 Ford Pickup F350 AIR BAG RESTRAINT SYSTEM (F150 & F250 LD) 1997 ACCESSORIES/SAFETY EQUIPMENT Ford Motor Co. - Air Bag Restraint System

DISABLING SYSTEM Disconnect ground battery cable. SRS contains a back-up power supply built into air bag diagnostic monitor. Wait at least one minute before servicing any air bag components. System is now disabled. To activate SRS, see ACTIVATING SYSTEM . ACTIVATING SYSTEM Connect ground battery cable. System is now activated. From outside of vehicle (driver-side), turn ignition switch to RUN position. Check AIR BAG warning light for system fault codes. Perform system operation check to ensure SRS is functioning properly. See SYSTEM OPERATION CHECK . COMPLETE SYSTEM DEACTIVATION  Vehicle was involved in a collision, air bag did not deploy, and vehicle needs to be driven.  SRS is not functioning properly, and vehicle needs to be driven.  Diagnosis and testing purposes. 1. Disconnect ground battery cable. Wait at least one minute to deplete charge in back-up power supply. Remove driver-side air bag module. See DRIVER - SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. Connect Air Bag Simulator (105-00010) to harness at top of steering column. 2. Remove passenger-side air bag module. See PASSENGER - SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. Connect Air Bag Simulator (105-00010) to harness in place of air bag module. Reconnect ground battery cable. To reactivate SRS, see COMPLETE SYSTEM REACTIVATION . BATTERY. NOTE: Following disabling procedure should be used for component replacement purposes only. If vehicle was involved in a collision and air bag did not deploy or if SRS is not functioning properly, and vehicle needs to be driven, complete system deactivation is required. See COMPLETE SYSTEM DEACTIVATION . WARNING: Back-up power supply will hold a deployment charge for approximately one minute after positive battery cable is disconnected. Servicing SRS before one minute may cause accidental air bag deployment and possible personal injury. Always deactivate driver-side module before attempting any service procedures. NOTE: Complete system deactivation sequence is required for following situations: 1997 Ford Pickup F350 AIR BAG RESTRAINT SYSTEM (F150 & F250 LD) 1997 ACCESSORIES/SAFETY EQUIPMENT Ford Motor Co. - Air Bag Restraint System

Fig. 2: Installing Air Bag Simulator Courtesy of FORD MOTOR CO. COMPLETE SYSTEM REACTIVATION 1. Disconnect ground battery cable. Wait at least one minute to deplete charge in back-up power supply. Remove Air Bag Simulator (105-00010) from harness connector at steering wheel. Install driver-side air bag module. See DRIVER - SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. 2. Remove Air Bag Simulator (105-00010) from harness connector on passenger-side. Install passenger-side air bag module. See PASSENGER - SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. Reconnect ground battery cable. System is now reactivated. Check AIR BAG warning light for proper system function. See SYSTEM OPERATION CHECK . DISPOSAL PROCEDURES Air bag disposal may be necessary in following situations:  Scrapping vehicle with deployed air bag.  Scrapping vehicle with live air bag. WARNING: Refer to SERVICE PRECAUTIONS before proceeding. 1997 Ford Pickup F350 AIR BAG RESTRAINT SYSTEM (F150 & F250 LD) 1997 ACCESSORIES/SAFETY EQUIPMENT Ford Motor Co. - Air Bag Restraint System

 Disposal of a live but electrically faulty air bag module.  Disposal of a deployed air bag module. AIR BAG DISPOSAL PROCEDURES DEPLOYED AIR BAG Dispose of deployed air bag module as any other part. Air bag module components are not reusable. UNDEPLOYED AIR BAG - FAULTY UNIT If an undeployed air bag module is diagnosed as faulty, remove air bag module and return intact to Ford Motor Company for proper disposal. Return carton for warranty claim credit. Air bag must be packaged and shipped according to U.S. Department of Transportation. Retain replacement packaging including label. DO NOT deploy air bag. SCRAPPED VEHICLE If vehicle is to be scrapped, undeployed air bag module must first be deployed. Use one of following procedures for deployment of air bag. Procedure 1: Remote Deployment Of Air Bag This procedure is to be used when a vehicle with a live driver-side air bag is to be scrapped, but a problem in air bag electrical system prevents deployment with air bag still installed in vehicle. This procedure can also be used Condition Instructions Module Replacement Deployed Air Bag (1) Dispose Of In Usual Manner Faulty But Live Air Bag Module (2) Return For Disposal Vehicle To Be Scrapped Deployed Air Bag (1) Dispose Of In Usual Manner Live Air Bag (3) Deploy Air Bag Using PROCEDURE 1 (1) See DEPLOYED AIR BAG . (2) See UNDEPLOYED AIR BAG . (3) See SCRAPPED VEHICLE . CAUTION: DO NOT dispose of undeployed air bag module without first deploying air bag. If this is not possible through procedures outlined, contact vehicle manufacturer for further instructions. 1997 Ford Pickup F350 AIR BAG RESTRAINT SYSTEM (F150 & F250 LD) 1997 ACCESSORIES/SAFETY EQUIPMENT Ford Motor Co. - Air Bag Restraint System

if PROCEDURE 1 was unsuccessful. 1. Before proceeding, see SERVICE PRECAUTIONS . Deactivate SRS. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove driver-side and/or passenger-side air bag module. See DRIVER-SIDE AIR BAG MODULE and PASSENGER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION . 2. With air bag module removed, cut air bag connector from wiring harness near air bag module. Strip 1" of insulation from wire ends. Obtain 2 wires at least 20 feet long. Connect one end of each 20-foot wire to one end of each air bag module wire. 3. Place air bag module with trim cover facing upward on a flat surface, in remote area such as parking lot or field. Remain at least 20 feet away from air bag module. Deploy air bag by touching loose ends of both wires to 12-volt battery terminals. 4. If successful, a loud noise will be heard and bag material will be visible. Allow at least 10 minutes for cooling and dissipation of air bag effluents before approaching air bag. Air bag is now inoperative. If air bag does not deploy, air bag module is faulty. Contact vehicle manufacturer for further instructions on disposal procedures. POST-COLLISION INSPECTION When a vehicle has been involved in a collision, certain components of the passive restraint system must be inspected or replaced. See PASSIVE RESTRAINT SYSTEM INSPECTION article in the GENERAL INFORMATION section for post-collision inspection information. ADJUSTMENTS CLOCKSPRING Rotate clockspring rotor counterclockwise until it stops, then rotate clockwise two revolutions. Clockspring is now aligned. WIRE REPAIR To repair damage to sensor wiring and wiring harnesses, note the following conditions and proceed to REPAIR PROCEDURE.  All wire splice connections must be staggered at least 2" (50 mm) apart. WARNING: Perform remote deployment outdoors. Keep all personnel at least 20 feet away to ensure physical and hearing safety from projected objects and loud noise of air bag deployment. WARNING: When placing a live air bag on a bench or other surface, always face air bag and trim cover up and away from surface. This will reduce motion of air bag module if it is accidentally deployed. 1997 Ford Pickup F350 AIR BAG RESTRAINT SYSTEM (F150 & F250 LD) 1997 ACCESSORIES/SAFETY EQUIPMENT Ford Motor Co. - Air Bag Restraint System

 Use appropriate solder (rosin core) and proper size heat shrink tubing for size of wire being spliced.  All repaired connections must be waterproofed using heat shrink tubing. Repair Procedure Cut shrink tubing about 2" long. Slide shrink tubing onto one wire end first. Strip wire ends and twist firmly together. Solder connection using rosin core, mildly activated solder. Flatten connection against wires, and slide heat shrink tubing over solder joint leaving 1/2" of tubing on each side of connection. See Fig. 3 . Using heat gun, hair dryer, or match, heat tubing until it shrinks and adhesive oozes from each end of tubing. Connection is now waterproofed. 1997 Ford Pickup F350 AIR BAG RESTRAINT SYSTEM (F150 & F250 LD) 1997 ACCESSORIES/SAFETY EQUIPMENT Ford Motor Co. - Air Bag Restraint System

1997-2004 Ford F-250 / F-350 Service & Repair Manual

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