Ford Fusion: Front Seats / Front Seat Track Motor. Removal and Installation

Special Tool(s) / General Equipment

Removal

  WARNING: The following procedure prescribes critical repair steps required for correct restraint system operation during a crash. Follow all notes and steps carefully. Failure to follow step instructions may result in incorrect operation of the restraint system and increases the risk of serious personal injury or death in a crash.

All seats

1.   WARNING: Turn the ignition OFF and wait one minute to deplete the backup power supply. Ignition must remain OFF until repair is complete. Failure to follow this instruction may result in serious personal injury or death in the event of an accidental deployment.

   Turn the ignition off and wait at least one minute.
   

1. 1. If equipped.
      Move the front seat to the full upward position.
      
   2. Move the front seat to the full rearward position.
      

1. Remove the side shield screws and position aside the side shield.
   

1. 
   Remove the side shield.
   
   1. Lift up on the rear of the side shield and pull outward.
      
   2. Push the side shield forward.
      
   3. Disconnect the electrical connector.
      

Passenger seat

1. Disconnect the OCS electrical connector.
   

All seats

1. Release the cushion cover front J-clip.
   Use the General Equipment: Pick Hook

1. Invert the front of the cushion cover.
   

1. On both sides.
   Release the cushion cover J-clips.
   

1. NOTICE: If equipped with heated seat or an OCS service kit, do not lift the seat cushion to far or damage to the cushion heater mat pigtail (if equipped) or the OCS service kit parts (if equipped) can occur.

   Position the front seat cushion upward.
   

Passenger seat

1. NOTE: Original equipment OCS shown, OCS service kit similar.

   Remove the OCS pin-type retainers and position the OCS bladder upward.
   

1. Remove the OCS bracket screw and position aside the electrical wiring harness.
   

1. NOTE: Note the location of the OCS hose as it passes through the seat cushion support to ensure proper installation.

   If equipped with OE (original equipment) OCS.
   Remove the OCS sensor.
   

Heated seats

1. Release the retainers and disconnect the electrical connector.
   

All seats

1. Detach the backrest cover strap and position aside the electrical connectors.
   

1. Release the cushion cover J-clips and wiring harness retainers.
   

1. Remove the front seat cushion cover.
   

1. Release the retainers.
   

1. Release the hooks and remove the front seat cushion support assembly.
   

1. Disconnect the front seat track motor electrical connector, release the retainers and position the wire harness aside.
   

1. Release the retainers and position the wire harness aside.
   

1. Remove the bolts and the front seat track motor and bracket assembly.
   

Installation

All seats

1. NOTE: Use the bolts from the old motor and bracket assembly.

   On both sides.
   Install the front seat track motor bolts.
   Torque: 21 lb.ft (28 Nm)

1. NOTICE: When using a drill to move the seat track, do not move the seat track to its forward or rearward end of travel stops, otherwise a new seat track must be installed.

   NOTE: Be sure to drive the seat track evenly or the track will bind during movement.

   NOTE: Rotate the cables using 2 drills operating at similar speeds to most efficiently position the seat track.

   Insert the original seat track motor cables and drive the gearbox and seat track uniformly until the rear edge of the upper and lower seat tracks are aligned.
   Use the General Equipment: Electric Drill

1. The rear edges of the upper and lower seat track rails must align with each other on both sides.
   

1. On both sides.
   Remove and discard the front seat track motor bolts.
   

All seats

1. NOTE: Install a new seat track if the block is not in place.

   Verify the block is in place at the rear of the inboard seat track rail.
   

1. Pull the long cable on the new motor assembly out of the sheathing, as shown, to aid installation.
   

1. Insert the long drive cable into the seat track gearbox.
   

1. Rotate the long drive cable to verify engagement to the seat track gearbox.
   

1. NOTICE: Do not severely bend the short cable during installation or damage to the cable will occur.

   1. Position the seat track motor while inserting the short cable into the seat track gearbox.
      
   2. Rotate the short drive cable to verify engagement to the seat track gearbox.
      

1. NOTICE: Do not cross-thread the bolts, they are load bearing. If the bolts are cross-threaded, a new seat track must be installed.

   Install the new front seat track motor bolts in the sequence shown.
   Torque: 21 lb.ft (28 Nm)

1. Reposition the wire harness and engage the retainers.
   

1. Connect the front seat track motor electrical connector, reposition the wire harness and engage the retainer.
   

1. Attach the hooks and install the front seat cushion support assembly.
   

1. Engage the retainers.
   

1. NOTICE: Inspect the OCS bladder, seat cushion pan and support assembly for any foreign objects before installing the OCS to the seat cushion pan. Remove any foreign objects. Failure to follow these instructions may result in incorrect operation of the OCS and may cause system failure.

   NOTE: Passenger seat with OCS service kit shown, other seats similar.

   Feed the cushion heater mat pigtail (if equipped) and OCS hose (passenger seat only) between the seat cushion support wires.
   

1. NOTE: Reclining the backrest will aid in positioning the cushion foam pad and cover through the opening.

   Install the front seat cushion cover.
   

1. Attach the cushion cover J-clips and engage the wire harness retainers.
   

1. Attach the backrest cover straps and connect the electrical connectors.
   

Heated seats

1. Connect the electrical connector and engage the retainers.
   

Passenger seat

1. Position the electrical wiring harness and install the OCS bracket screw.
   Torque: 27 lb.in (3 Nm)

1. Connect the passenger seat OCS electrical connector.
   

1. NOTE: Original equipment OCS shown, OCS service kit similar.

   Install the OCS sensor and the pin-type retainers.
   

All seats

1. Attach the cushion cover J-clip.
   

1. On both sides.
   Attach the cushion cover J-clips.
   

1. Connect the seat control switch electrical connector.
   

1. 1. Connect the electrical connector.
      
   2. Position the cushion side shield onto the seat track and slide rearward to engage into the bracket.
      
   3. Position the side shield to the recliner and engage the retainers.
      

1. Install the front seat cushion side shield screws.
   

1. On a driver seat with memory, operate the seat track horizontal motor in all directions through the full range of travel to set the soft stops and avoid a premature stopping point occurrence after the vehicle is returned to the customer.
   

Passenger seat

1.   WARNING: Occupant Classification System (OCS) parts are calibrated as an assembly and must only be replaced in the configuration they are sold. Never separate parts of an assembly. Failure to follow this instruction may result in incorrect operation of the OCS and increases the risk of serious personal injury or death in a crash.

     WARNING: Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before using System Reset to rezero the seat weight. Failure to follow these instructions may result in incorrect operation of the occupant classification system (OCS) and increases the risk of serious personal injury or death in a crash.

   NOTICE: To prevent system failure, take the following precautions before carrying out the OCS reset.

   • Make sure the voltage to the OCSM is greater than 8 volts and less than 18 volts.
   • Make sure the OCS is not below 42.8 °F ( 6 °C) or above 96.7 °F ( 36 °C) when initiating the OCS reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature between 42.8 °F ( 6 °C) to 96.7 °F ( 36 °C) for a minimum of 30 minutes.
   • Make sure nothing is present on the passenger seat before and during the OCS reset process.
   • Prior to carrying out the OCS reset, make sure a minimum of 8 seconds has elapsed after cycling the ignition on.
   Using a diagnostic scan tool, carry out the OCS reset. Cycle the ignition after the OCS reset.
   

1. If the first system reset attempt was successful, proceed to prove out the SRS.
   

1. If the first system reset attempt was not successful, carry out a thorough visual inspection of the OCS connector and wiring for damage, pressure sensor hose for kinks and or damage, and seat-related wiring harness and body wiring harness terminals and connectors for damage. Repair any concerns found and proceed to the next step.
   

1. Carry out a second OCS reset. If the second attempt is unsuccessful, install a new OCS service kit.
   Refer to: Occupant Classification System (OCS) Sensor (501-20B Supplemental Restraint System, Removal and Installation).
   

1. Prove out the SRS by turning the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back to ON and monitor the airbag warning indicator with the airbags installed. The airbag warning indicator illuminates continuously for approximately 6 seconds and then turns off. If a SRS fault is present, the airbag warning indicator will fail to light, remain lit continuously, or flash.
   

1. • If a SRS fault is present, the airbag warning indicator either fails to light, remains lit continuously or flashes. The flashing may not occur until approximately 30 seconds after the ignition has been turned from OFF to ON. If this occurs, diagnose and repair any SRS faults before proceeding with other repairs.
     
   • If, after the ignition has been turned on for 30 seconds, the airbag warning indicator remains unlit with no chime or SRS message displayed in the message center, no SRS fault is present.
     
   • If the airbag warning indicator is inoperative and a SRS fault exists, a chime sounds in a pattern of 5 sets of 5 beeps or a message displays in the message center. If this occurs, diagnose and repair the airbag warning indicator and any SRS faults before proceeding with other repairs.
     

1. Using a diagnostic scan tool, clear all Continuous Memory Diagnostic Trouble Codes (CMDTCs) from all modules.