2013 Explorer Interceptor Repairs

Discussion in 'Explorers - Expeditions - Excursions - Broncos -Es' started by Roush PSD Interceptor, Sep 15, 2019.

  1. Roush PSD Interceptor

    Roush PSD Interceptor Straight Piped Diesel Staff Member

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    Right rear side pad replacement done.
    Caliper bolts are only torqued to 24 ft. lbs.
    Takes just the right pressure on the piston wind back tool to work it smoothly.
    Notice how I made a work station for winding back piston and cleaning clip mounts to place pads in.
    The inside pad had delamination from the backing plate.

    Set the ride height to 19 3/4" same as before disassembly using a pump jack
    on the lower steel swing arm. Loosely mount top swing arm to knuckle with bolt/nut.
    Loosely mount lower shock bolt. Push inward on top of rotor for total negative camber
    then tighten top swing arm to knuckle mount to 148 ft. lbs.. Tighten lower swing arm to knuckle bolt/nut to 195 ft. lbs.
    Tighten lower shock mount bolt to 129 ft. lbs. Tighten toe link bolt nut to knuckle to 59 ft. lbs.
    Position upper stabilizer link in knuckle mount and tighten stabilizer upper link nut to 41 ft. lbs.
    Mount caliper mounting bracket to knuckle and tighten bolts to 76 ft. lbs.

    Waiting on wife to tighten the axle shaft nut to 258 ft. lbs.

    Has to be done with wheel off using old nut first to set splines in bearing
    at that torque setting then remove old nut and apply new nut while someone holds the brake, not e-brake.
    Once new nut is tightened, 5 minutes cannot elapse before torquing to 258 ft.lbs.
    The thread locker on the threads is heat activated.

    If done with weight of the vehicle on bearing, damage can be done to wheel bearing.

    Finish cleaning diff housing of old gasket material, diff cover is clean. Permatex Gear Oil Gasket Maker
    Oil Resistant to be used. Has 15 minute work time.
    Fill diff with Lucas 80w90 gear oil and 1/4 amount of Lucas Synthetic Stabilizer
    3mm below fill plug (using finger to judge this).

    Check all fluids and remote start Ceptor.
    [​IMG][​IMG][​IMG][​IMG]
     
    Last edited: Sep 25, 2019
  2. Roush PSD Interceptor

    Roush PSD Interceptor Straight Piped Diesel Staff Member

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    Have to wait 24hrs. for Permatex Oil Resistant Gasket Maker to cure before adding 80w90 blend lube.[​IMG][​IMG]

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  3. Roush PSD Interceptor

    Roush PSD Interceptor Straight Piped Diesel Staff Member

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    It has been 300+ miles since the repair and no leaks from the differential.
    You can see in the first pic the zero negative camber preset as defined by the
    assembly manual instructions.

    Then the wife tells me the CEL is back on. Checked the code, it was a P2251.
    means that the powertrain control module (PCM) has detected a negative current discrepancy in the upstream oxygen (O2) sensor for engine bank number one. ... Sensor 1.
    Sensor 1 is cylinder 1 on the 3.7L it is the front rear. Just had new catalytic converters replaced at no charge.
    This tells me the upstream oxygen sensor is not reading.

    Broke out the endoscope and found this: (see video below)
    Ultimately called the Fixed Operations Director at the Ford of Dalton we took it to for the recall 19E02
    and explained what happened.
    He told the Service Manager to expect us to set up a meeting look at the "Ceptor".
    He said they would get with the techs and figure out what happened, get on to them and "get to the bottom of this".

    Service manager looked at my video and my verbal description of what I found and said they would check it out to see why it was left that way. Also told him about the lower exhaust bracket being left lose and showed him the video of that. Unacceptable he said. He apologized.

    Today they called saying they saw the damage and do not know how it happened. Parts are on order to replace engine harness and O2 sensor AT NO CHARGE, should be here Monday, finished Tuesday, October 15th.
    Looked like it was burned and then wires probed to find out why it wasn't making continuity on the yellow and blue wires, then left that way by the tech. WTH?
    In the video, due to the color of the endoscope's led, the blue wire appears orange and the yellow wire looks light blue.

    I pointed out to the Service Manager why is the black wire burned at the O2 sensor down
    by the catalytic converter with no possible way for it to touch any part of the heat shield
    or catalytic converter due to the length of the wire where it was burned.

    I would hope that when the tech described in the repairs, that 4 exhaust studs broke off due to being cross threaded (most likely differing metal electrolysis, aluminum head to steel stud), that they didn't use heat from a torch to try and remove them because later in the repair description they said they had to go and source a stud remover.


    20191008_175733.jpg

    20191008_175743.jpg
     
  4. Roush PSD Interceptor

    Roush PSD Interceptor Straight Piped Diesel Staff Member

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    Also installed both inside A-pillar interior covers where the spotlights
    had been drilled through for the hand controls. Right or passenger side
    had an oh shizz handle was the only complication.
    7mm socket fit those fine threaded bolts.
    Press to fit metal clips along the pillar and plastic tabs in the lower portion.
    Did get to see the side curtain airbag setup.

    The wife had bought these stick on black round covers for the holes that
    were exposed from removing the Unity spotlights, but those fell off in the
    first hot day. Told her so.
     
  5. Roush PSD Interceptor

    Roush PSD Interceptor Straight Piped Diesel Staff Member

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    After going around in circles with Ford of Dalton on fixing the F'ups Tech A86 created during Recall 19E02,
    the recently discovered missing retainers in the wiper cowl plastic to top of firewall
    (why in the world were they in there?)
    and missing nut on the exhaust stud after the twin flex pipes causing a leak,
    I decided to never take it back there again.
    Even found a pair of 14" heavy duty, long nose pliers laying on the wiper cowl and a
    cut off tip tie.
    Everytime I found something missing of damaged it was half done repaired or not at all.

    Crap work on recalls, you are a paying customer you may get what they call "premier service" or "factory trained
    techs". Looks like Tech A86 was trained using our Explorer Interceptor as the guinea pig.

    You always hear the stories of people who finish working on a vehicle and have a handful of nuts and bolts left over?
    I don't even think they realized they were missing when they put our vehicle back together.

    Only reason we took it there was the wife works 24hr. shifts and this is the closest Ford Dealer whom I had great service
    from in the past plus it was a recall from Ford.


    missing exhaust bolt.jpg
     
  6. Roush PSD Interceptor

    Roush PSD Interceptor Straight Piped Diesel Staff Member

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    P0456 code again.
    Has been 700 miles since the last time it registered.
    I still have to do a tune up that requires intake manifold removal.
    I have the silicone gaskets and SP-500 plugs ready.
    I'll get to track down the EVAP lines better at that time.

    After clearing the CEL, the remote start stopped working.
    Have to look with FORScan at the BCM to see if anything changed.

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