Shift Interlock System: Removal & Installation — Mercury Sable IV (1999-2005)

REMOVAL & INSTALLATION

WARNING

Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.

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 article in GENERAL INFORMATION before disconnecting battery.

Removal & Installation (Crown Victoria, Grand Marquis, Sable & Taurus)

Disconnect the battery ground cable. Remove the Brake Pedal Position (BPP) switch. Remove the clip. (Scheme 97) Remove the retainer. Disconnect the harness connector. Remove the BPP switch. To install, reverse the removal procedure.

Scheme 95

Scheme 95: Removal & Installation (Crown Victoria, Grand Marquis, Sable & Taurus)

Removal & Installation (Econoline, F150 Pickup & Town Car)

Disconnect the negative battery cable. Remove left side instrument panel trim panel. Remove the left side instrument panel insulator.
Disconnect the courtesy light. Disconnect the Brake Pedal Position (BPP) switch harness connector. Remove the BPP switch. (Scheme 98) Remove the self-locking pin.
Remove the BPP switch from the brake master cylinder push rod. Remove the brake master cylinder push rod spacer. Remove the brake master cylinder push rod bushing. To install, reverse the removal procedure.

Scheme 96

Removal & Installation (Escape & LS)

Remove the instrument panel insulator. Remove the Brake Pedal Position (BPP) switch. Disconnect the harness connector. Rotate clockwise and remove the BPP switch. (Scheme 99)or (Scheme 100).
To unlock, rotate the lock knob counterclockwise to the stop. (Scheme 101) With the engine running, fully depress and hold the brake pedal. Install the BPP switch.
Position the BPP switch in the bracket and rotate counterclockwise. (Scheme 102)or (Scheme 103). Connect the harness connector. Slowly release the brake pedal.

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Removal & Installation (Escort & ZX2)

Disconnect the battery ground cable. Disconnect the Brake Pedal Position (BPP) switch harness connector. (Scheme 104) Loosen the BPP switch lock nut and remove the switch. (Scheme 105) To install, reverse the removal procedure.

Scheme 102

Scheme 102: Removal & Installation (Escort & ZX2)

Scheme 103

Removal & Installation (Explorer & Mountaineer)

Remove the Brake Pedal Position (BPP) switch. Disconnect the BPP harness connector. Remove the retaining pin (2). (Scheme 106) Remove the BPP switch (3). To install, reverse the removal procedure.

Scheme 104

Scheme 104: Removal & Installation (Explorer & Mountaineer)

Removal & Installation (Focus)

Detach the instrument panel lower trim panel. Remove the screws. (Scheme 107) Release the fastener. Remove the instrument panel lower panel. Disconnect the hood release cable. (Scheme 108)
Disconnect the data link harness connector. Detach the Brake Pedal Position (BPP) switch harness connector. (Scheme 109) Unlock the BPP switch. Detach the BPP switch.
To install, set the brakelight switch by pulling the switch plunger out to its full extent. (Scheme 110) Depress the brake pedal and SLOWLY release the brake pedal.
Install BPP switch harness connector. (Scheme 109) Lock the BPP switch in position. Attach the instrument panel lower panel. Connect the hood release cable. (Scheme 108)
Connect the data link harness connector. Install the instrument panel lower panel. Attach the fastener. (Scheme 107) Install the screws.

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Removal & Installation (Villager)

Disconnect the battery ground cable. Remove the Brake Pedal Position (BPP) switch. Disconnect the harness connector (1). (Scheme 111) Loosen the lock nut (2). Remove the BPP switch (3). To install, reverse removal procedure. Adjust the BPP switch. See BRAKE PEDAL POSITION SWITCH under ADJUSTMENTS. Connect the negative battery cable.

Scheme 109

Scheme 109: Removal & Installation (Villager)

Removal & Installation (Sable, Taurus & Town Car - Floor Shift)

Disconnect the negative battery cable. If equipped, disconnect the cellular phone antenna cable and coaxial cable. Remove the console glove compartment. Disconnect the power point harness connector.
If equipped, disconnect the cellular phone antenna cable and coaxial cable from the console glove compartment.
If equipped, remove the compact disc changer. Remove the screws. (Scheme 112) Disconnect the harness connector. Remove the digital audio compact disc player. Place the gearshift lever in the "1" position.
Remove the console top panel. Disconnect the cigar lighter harness connector. Remove the floor console-to-floor bracket screws. (Scheme 113)or (Scheme 114).
Remove the floor console-to-gearshift bracket screws. (Scheme 116) On Sable and Taurus, remove floor console-to-floor bracket screws. (Scheme 115) On all models, remove the floor console. Slide the floor console rearward. (Scheme 117) On all models, remove the floor console. Disconnect the 3 harness connectors. To install, reverse the removal procedure. On Town Car, tighten console-to-gearshift and console-to-floor bracket screws to 24-33 INCH lbs. (2.7-3.7 N.m) and CD changer screws to 11-16 INCH lbs. (1.2-1.8 N.m). On Sable and Taurus, tighten all screws to 89 INCH lbs. (10 N.m).

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Removal & Installation (LS)

Apply the parking brake. If equipped with an automatic transmission, place the selector lever in neutral. Disconnect the battery ground cable. Remove the ashtray finish panel. (Scheme 118)
Disconnect the harness connectors. If equipped with a manual transmission, remove the gearshift lever knob. If equipped, disconnect the cellular phone harness connectors. Remove the console finish panel assembly by pulling upward from the front first. (Scheme 119)
If equipped, disconnect the traction control switch harness connector. If equipped, release the cellular phone wiring harness from the console finish panel assembly. To install, reverse the removal procedure.

Scheme 116

Scheme 117

Disconnect the battery ground cable. Remove the left side scuff plate. Release the retaining clips and remove the left side "A" pillar lower trim panel.
Remove the lower instrument panel finish panel. Remove the courtesy light from the instrument panel finish panel. Position the driver side carpet aside.
Position interior Auxiliary Junction Box (AJB) aside. Remove the nuts (1) and position the AJB aside (2). (Scheme 120) Remove the nuts, bolt and position the Front End Module (FEM) aside.
Disconnect the harness connectors (1). (Scheme 121) Remove the FEM (2). To install, reverse the removal procedure and tighten FEM bolts. (Scheme 122)

Scheme 118

Scheme 119

Scheme 120

Removal & Installation (Cougar)

Raise and support vehicle. Remove lower heat shield covering access to gearshift lever mounting nuts. Disconnect gearshift lever cable adjusting cap and gearshift lever cable. Remove 4 gearshift lever mounting nuts. (Scheme 123)
Lower vehicle. Remove the front ash receptacle and lighter element. Remove the lighter trim, if equipped. Remove gearshift lever cover. Lift gearshift lever assembly upwards and disconnect gearshift lever harness connector. (Scheme 124)
Install the selector lever assembly. (Scheme 124) Reconnect the selector lever harness connector. Position the selector lever. Install the cover.
Install the lighter trim, if equipped. Install the lighter element and the front ash receptacle. Raise the vehicle. Install the selector lever assembly.
Install the nuts. (Scheme 125) Do not lock the selector cable adjusting cap. Connect the selector cable. Install the heat shield. Lower the vehicle. Adjust the cable and selector lever. See appropriate AUTOMATIC article in TRANSMISSION SERVICING. Connect the negative battery cable.

Scheme 121

Scheme 122

Scheme 123

Remove the transmission control selector dial bezel. See «SELECTOR DIAL BEZEL»(ref-140004-S18241715292002060300000). Disconnect the shift interlock actuator harness connector.
Disconnect the park range switch harness connector. Remove the screws and the shift interlock actuator. (Scheme 126) Remove the gearshift lever cable nut. (Scheme 127)
Be careful not to kink the shift cable and bracket when repositioning it aside to avoid cable binding. Remove the cable floorpan bracket bolts. (Scheme 128)
Hold the ignition/shifter interlock cable lock nut (A) to prevent it from turning while loosening the ignition/shifter interlock cable lock nut (B), and position the cable aside. (Scheme 129) Remove the nuts and remove the gearshift lever. (Scheme 130)
To install, reverse the removal procedure. When tightening ignition/shifter interlock cable lock nut, torque to 87-130 INCH lbs. (9.8-14.6 N.m). Adjust the shift cable and bracket. See appropriate AUTOMATIC article in TRANSMISSION SERVICING. Adjust the transmission control selector dial bezel. See «SELECTOR DIAL BEZEL»(ref-140004-S07970653792002060300000) under ADJUSTMENTS.

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Remove center console front cup holder insert. Remove 2 center console retaining screws. Remove rear cup holder insert. Remove 3 nuts retaining center console. Remove parking brake boot from parking brake handle. Remove parking brake boot from center console. Raise parking brake handle and lock in place.
Place gearshift lever in Park position. Remove center console. Unclip gearshift lever cable. (Scheme 131) Unclip and remove gearshift lever cable outer sleeve from gearshift lever assembly. Disconnect gearshift lever assembly harness connector. Remove 4 nuts retaining gearshift lever assembly to floor pan. (Scheme 132) Remove gearshift lever assembly.
To install, reverse removal procedure. Coat gearshift lever assembly retaining bolts with thread locking compound. Tighten 4 nuts retaining gearshift lever assembly to floor pan to 80 INCH lbs. (9 N.m).
Adjust gearshift cable by placing gearshift lever in Drive position. Raise and support vehicle. Ensure gearshift cable outer sleeve is free for moving after unlocking.
Unlatch gearshift cable locking mechanism (turn counterclockwise). (Scheme 133) Ensure Transmission Range (TR) sensor alignment marks are aligned with transaxle manual lever. (Scheme 134) Move transaxle manual lever to Drive position. Latch gearshift cable locking mechanism (turn clockwise). Lower vehicle and check gearshift cable adjustment.

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Remove the front screw of shift knob. Position the gearshift lever to gain access. Remove the right side screw and the gearshift knob. Remove the floor console. Remove the screws from the transmission control selector dial bezel. Disconnect the indicator light socket and remove the bezel. Adjust the transmission control selector dial bezel, and then tighten the screws in the sequence shown. (Scheme 96) To install, reverse the removal procedure. Use Threadlock and Sealer (EOAZ-19554-AA) meeting Ford specification WSK-M2G315-A5 (Type II) when installing the gearshift lever knob screws. Tighten the front screw to 18-26 INCH lbs. (2.0-2.9 N.m).

Removal & Installation (Town Car - Floor Shift)

Note. Manufacturer does not supply removal and installation information on Town Car column shift models.

Remove the center console. See «CENTER CONSOLE»(ref-140004-S10271580122002060400000). Remove the ignition/shifter interlock cable from the bracket and the shifter interlock cam. (Scheme 135) Remove the left lower instrument panel trim. (Scheme 136)
Remove the nuts, and lower the steering column. (Scheme 137) Disconnect the shift interlock harness connector. (Scheme 138) Remove the screws. (Scheme 139) Remove the ignition/shifter interlock cable from the bracket. Remove the ignition/shifter interlock cable. (Scheme 140)
To install, position the ignition/shifter interlock cable. (Scheme 135) Connect the ignition/shifter interlock cable to the shifter interlock cam and the bracket. Install the ignition/shifter interlock cable into the bracket.
Install the ignition/shifter cable bracket, and torque screws to 10-13 ft. lbs. (13-17 N.m). (Scheme 139) Connect the harness connector. (Scheme 138) Position the steering column and install the retaining nuts. (Scheme 137) Install the left lower instrument panel trim. (Scheme 136)
Check for proper interlock operation. The ignition key should be removable only with the transaxle range selector lever in Park. The transaxle range selector lever should be locked in the Park position with the key removed. Install center console. See «CENTER CONSOLE»(ref-140004-S10271580122002060400000).

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Scheme 137

Scheme 138

Removal & Installation (Crown Victoria & Grand Marquis)

Remove the instrument panel finish panel and disconnect the harness connector. (Scheme 141) Lift the console finish panel up and remove the finish panel.
Push the shift handle bezel down and disconnect the TCS harness. (Scheme 142) Remove the 2 shift handle retaining screws and remove the shift handle. (Scheme 143)
Lift the shift indicator bezel and remove the bulb. (Scheme 144) Release the shift interlock cable housing clip and disconnect the interlock cable. (Scheme 145)
Remove the lower steering column opening finish panel. (Scheme 146) Remove the screw and position the parking brake release handle out of the way.
Remove the screw from the lower steering column opening finish panel. Pull outward to release the retaining clips, and remove the lower steering column opening finish panel.
Remove the 5 screws and the lower steering column opening finish panel reinforcement. (Scheme 147) Remove the 4 screws and the instrument panel reinforcement brace. (Scheme 148)
Remove the 4 nuts, and lower the steering column. (Scheme 149) Disconnect the harness connector from the shift interlock actuator solenoid.
Remove the 2 screws from the actuator mounting cover. (Scheme 150) Lift the actuator solenoid from the mounting bracket, and remove the interlock actuator and cable. To install, reverse the removal procedure.

Scheme 139

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Removal & Installation (Econoline)

Note. On vehicles equipped with an auxiliary battery, both the negative and positive battery cables must be disconnected. On vehicles equipped with a 7.3L engine, both the primary and secondary batteries must be disconnected.

Disconnect the battery. Remove the instrument panel steering column cover, the driver-side knee brace and the instrument panel steering column opening cover reinforcement. (Scheme 151)
Disconnect all necessary harness connectors, and separate the harness bracket from the steering column. (Scheme 152) Remove the shift indicator cable and position it aside. (Scheme 153)
Remove the nuts, and lower the steering column. (Scheme 154) Remove the shift interlock actuator bolts and disconnect the harness connector. (Scheme 155)
To install, reverse the removal procedure. Ensure the shift cable and the shift indicator cable are correctly adjusted. Verify shift interlock actuator operation.

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

Removal & Installation (Escape)

Remove the clockspring. See appropriate AIR BAG RESTRAINT SYSTEMS article in ACCESSORIES & EQUIPMENT. Remove the multifunction switch. See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT.
Remove the windshield wiper/washer switch. See appropriate WIPER/WASHER SYSTEMS article in ACCESSORIES & EQUIPMENT.
Remove the ignition switch. See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT.
Disconnect the gearshift cable. (Scheme 156) Disconnect the harness connector.
Disconnect the wiring harness from the gear shifter assembly. Remove the bolts and the gearshift lever assembly. (Scheme 157) To install, reverse the removal procedure

Scheme 154

Scheme 155

For removal & Installation of shift interlock actuator, see REMOVAL & INSTALLATION (ESCORT & ZX2) under GEARSHIFT LEVER UNIT.

Removal & Installation (F150)

Remove the steering column. See appropriate STEERING COLUMNS article in STEERING. Remove the insert plate and shift interlock actuator. Remove the bolts. (Scheme 155)
The shift interlock actuator clip is an assembly aid for the assembly plant, and does not need to be replaced in the field. Remove the insert plate from the shift interlock actuator. Remove and discard the shift interlock actuator clip. (Scheme 158)
To install, follow the removal procedure in reverse order. On F150, torque shift interlock actuator bolts to 80 INCH lbs. (9 N.m). On all others, torque shift interlock actuator bolts to 62-98 INCH lbs. (7-11 N.m).

Scheme 156

If installation of a new brake shift interlock actuator is required, a new steering column must be installed. See appropriate STEERING COLUMNS article in STEERING.

If equipped with the traction control switch, the switch will need to be disconnected prior to removing the center console. Remove the center console. See «CENTER CONSOLE»(ref-140004-S10271580122002060400000). Remove the PRNDL indicator bulb. Remove the rear A/C air duct. (Scheme 159) Rotate the shifter bezel. (Scheme 160)
Disconnect the cable from the lever. Remove the shift interlock cable from the bracket. (Scheme 161) Disconnect the cable from the lever. Remove the lower steering column cover screws. (Scheme 162) Remove the instrument panel steering column cover.
Disconnect the harness connector. (Scheme 163) Remove the screws (1). (Scheme 164) Position the hood release cable and bracket aside (2). Remove the floor heat duct screw. (Scheme 165) Remove the lower reinforcement panel. (Scheme 166)
Remove the inner instrument panel finish panel. (Scheme 167) Remove the outer instrument panel finish panel. Disconnect the power mirror switch. (Scheme 168) Remove the inner trim support panel. (Scheme 169)
Remove the ignition switch. Remove 2 screws for the shift interlock actuator cable. (Scheme 170) Disconnect the harness connector. (Scheme 171) Remove the cable from the bracket and remove the cable. (Scheme 172) To install, reverse the removal procedure.

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

Removal & Installation (Sable & Taurus)

Remove the center console. See «CENTER CONSOLE»(ref-140004-S10271580122002060400000). Remove the ignition/shifter interlock cable from the floor shift. (Scheme 135) Disconnect the cable from the bracket. Disconnect the cable from the shift cam.
Remove the left side lower instrument panel trim. (Scheme 136) Disconnect 4 harness connectors. (Scheme 173) Remove the steering column support bracket. Remove the diagnostic harness connector bolts (1). (Scheme 174)
Remove the steering column support bracket bolts (2). Remove the nuts and lower the steering column. (Scheme 175) Disconnect the shift interlock harness connector. Remove the bolts.
Remove the ignition/shifter interlock cable and actuator assembly. (Scheme 140) Check for correct interlock operation. The ignition key should be removable only with the transaxle range selector lever in Park.
The transaxle range selector lever should be locked in the Park position with the key removed. To install, reverse removal procedure.

Scheme 171

Scheme 172

Scheme 173

Remove the steering column. See appropriate STEERING COLUMNS article in STEERING. Remove the screws. Remove the shift interlock actuator. (Scheme 176) To install, reverse the removal procedure. Tighten shift interlock actuator screws to 80 INCH lbs. (9 N.m).

Scheme 174

Scheme 174: Removal & Installation (Villager)

Place the vehicle in Neutral. Disconnect the battery cables. Remove the battery and tray. Disconnect the breather tube and Mass Air Flow (MAF) sensor. (Scheme 177) Remove the intake tube and air cleaner cover. (Scheme 178)
Remove the air cleaner assembly. Remove the thermostat housing. (Scheme 179) Remove the TR sensor.
Disconnect the TR sensor harness connector (1). (Scheme 180) Remove the bolts (2). Remove the TR sensor (3). Ensure the transaxle is in the Neutral position. Install the TR sensor and loosely install the bolts.
Using the TR Sensor Alignment Tool (T79L-70010-A), align the TR sensor and tighten the bolts. (Scheme 181) Connect the harness connector. Install the thermostat housing. Install the air cleaner assembly. Install the intake tube and air cleaner cover.
Connect the breather tube and Mass Air Flow (MAF) sensor. Before installing the battery tray, check the vent tube hose for any obstructions, kinks, or incorrect routing position.
Install the battery and tray. Connect the battery cables. Check the correct operation with parking brake control engaged. The engine should start only in Park or Neutral. Back-up lights should be active only in the Reverse position.