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2011 FORD FLEX Service Repair Manual .pdf



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2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

2009 ACCESSORIES & BODY, CAB
Instrument Panel and Console - Flex

SPECIFICATIONS
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Description

Nm
6
6
10
25
40
25
5
9
7
25
30
8

Front floor console lower bolts
Front floor console rear lower bolts
Ground wire bolts
Instrument panel center support bracket bolts
Instrument panel side bolts
Instrument panel upper cowl bolts
PCM nuts
Passenger side air bag-to-cross beam bolts
Rear floor console bolts
Steering column shaft-to-steering column bolt
Strut upper mount nuts
Thermostatic Expansion Valve (TXV) manifold bolt

lb-ft
18
30
18
18
22
-

lb-in
53
53
89
44
80
62
71

DESCRIPTION AND OPERATION
REFRIGERATOR
The rear floor console may be equipped with a refrigerator feature. The refrigerator operates only when the
ignition is in the ON position. The refrigerator should only be used when the engine is running. If there is a
need to use the unit when the engine is off, limit the time the refrigerator is running to avoid draining the
battery.
If the refrigerator is active and the ignition is turned to the OFF position, the refrigerator will also turn off. The
last known state of the refrigerator will be stored into the refrigerator module memory. When the ignition is
turned back to the ON position, the refrigerator/freezer will automatically activate to the last known state that is
stored in the refrigerator module memory.
The refrigerator/freezer is equipped with the following:





Refrigerator switch (located on rear floor console)
Compressor/motor assembly (not serviceable)
Refrigerant (not serviceable)
Refrigerator module (not serviceable)

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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Cool Mode

To activate the refrigerator, depress the refrigerator switch to the COOL position for approximately 1 second
until the COOL LED illuminates. When the refrigerator is in cool mode, the temperature will cool to
approximately 41°F (5°C). In order to turn the refrigerator off when the refrigerator is in cool mode, depress the
refrigerator switch to the COOL position for approximately 1 second, until the COOL LED turns off. When the
refrigerator is in the cool mode, the refrigerator can be switched to freeze mode by depressing the refrigerator
switch to the FREEZE position for approximately 1 second, until the COOL LED turns off and the FREEZE
LED illuminates.
Freeze Mode

To activate the freezer, depress the refrigerator switch to the FREEZE position for approximately 1 second,
until the FREEZE LED illuminates. When the refrigerator is in freeze mode, the temperature will cool to
approximately 23°F (-5°C). In order to turn the freezer off when the refrigerator is in freezer mode, depress the
refrigerator switch to the FREEZE position for approximately 1 second, until the FREEZE LED turns off. When
the refrigerator is in the freeze mode, the refrigerator can be switched to cool mode by depressing the
refrigerator switch to the COOL position for approximately 1 second, until the FREEZE LED turns off and the
COOL LED illuminates.
Diagnostic Mode

In the event of a system concern, the refrigerator is equipped with the capabilities to provide self diagnostics.
For information on the diagnostic mode, refer to the Principles of Operation located in REFRIGERATOR.

DIAGNOSIS AND TESTING
REFRIGERATOR
Special Tool(s)

SPECIAL TOOL REFERENCE CHART

73III Automotive Meter
105-R0057 or equivalent

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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Principles of Operation
Refrigerator

The refrigerator consists of a switch, module and motor assembly, which contains a cooling fan, refrigerant, a
condenser and a compressor. The refrigerator relay, located in the Battery Junction Box (BJB), controls voltage
to the refrigerator. The refrigerator relay coil is grounded at all times. When the ignition switch is in the RUN or
ACCESSORY position, voltage is supplied to the refrigerator relay coil from Smart Junction Box (SJB) fuse 34
(5A) and the relay closes. When the refrigerator relay is closed, voltage is sent to the refrigerator from BJB fuse
15 (15A).
The temperature of the refrigerator is controlled by a sensor located in the refrigerator module. When a
refrigerator mode is selected and the refrigerator temperature is above the target temperature, the compressor
will activate. If the temperature is below the target temperature, there is no need for cooling and the compressor
will stop. The compressor start up has a predetermined time delay to avoid a potential rapid changing
compressor on and off situation.
The heat from the compressor and condenser is pushed out of the vents of the refrigerator by means of a fan.
This fan runs continuously, as soon as a refrigerator mode is selected. The fan will not stop with the compressor
if the target temperature is reached.
Diagnostic Mode

The refrigerator can be switched into a diagnostic mode to read the potential error codes of the compressor.
When the refrigerator is in diagnostic mode, the COOL LED on the refrigerator switch will flash 1-5 times,
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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

depending on the error. Perform the following steps in order to access the refrigerator diagnostic mode:
1. Turn the ignition switch to the ON position.
2. Depress the refrigerator switch to the FREEZE position for approximately 1 second, until the FREEZE
LED illuminates.
3. Depress the refrigerator switch again to the FREEZE position for approximately 5 seconds, until the
FREEZE LED flashes quickly and repeatedly.
4.

NOTE:

Use the Diagnostic Mode Error Code Chart to determine the error.

When the FREEZE LED is quickly flashing, the COOL LED will display the error code by flashing 1-5
times, depending on the error.
NOTE:
5.

If the refrigerator is in diagnostic mode and the ignition is turned OFF, the
refrigerator will restart in FREEZE mode when the ignition is turned back
to the ON position.

To turn the diagnostic mode off, depress the refrigerator switch to the FREEZE position for approximately 1
second. The FREEZE LED will stop flashing, but it will remain illuminated and the refrigerator will be in
freeze mode.
DIAGNOSTIC ERROR CODE DESCRIPTION CHART
Number Diagnostic
Diagnostic Error Code Description
of Flashes Error Code
Battery
The voltage level at the refrigerator 12 volt connector is below the parameter
1
protection
settings. This code may set when the refrigerator has been active with the
cutout
engine off.
Fan overThe fan loads the electronic unit with more than 1 amp peak. Refer to
2
current cut-out INSPECTION AND VERIFICATION.
The rotor is blocked or the differential pressure in the unit is too high. This
may occur in high ambient temperature situations or if the refrigerator was
Motor start
3
stopped and restarted within a short period at a high load and/or a high
error
ambient temperature condition. Let the differential pressure lower, before
attempting to restart the refrigerator.
Minimum
The refrigeration system is so heavily loaded by ambient temperatures that the
motor speed motor cannot maintain a minimum speed of 1,850 rpm. Let the refrigerator
4
error
system cool down before attempting to restart the refrigerator.
The refrigerator is so heavily loaded by ambient temperatures that the
Thermal cutrefrigerator module gets too hot. Check the vents and the area of the
5
out of
compressor, condenser for a blockage, possibly from dust. Check the fan for
electrical unit
correct operation.
Inspection and Verification

1. Verify the customer concern.
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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

2. Visually inspect for obvious signs of mechanical or electrical damage:
VISUAL INSPECTION CHART
Mechanical





Refrigerator






Electrical

Battery Junction Box (BJB) fuse 15 (15A)
Smart Junction Box (SJB) fuse 34 (5A)
Refrigerator
Refrigerator relay
Refrigerator switch
Loose or corroded connections
Wiring harness

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.
4. If the concern is not visually evident, verify the symptom and GO to SYMPTOM CHART.
Symptom Chart

SYMPTOM CHART
Condition

Possible Sources





The refrigerator does not operate
correctly






Fuse(s)
Refrigerator relay
Refrigerator
switch
Refrigerator
Circuitry

Action



Go To PINPOINT TEST
A.

Pinpoint Tests
Pinpoint Test A: The Refrigerator Does Not Operate Correctly

Refer to SYSTEM WIRING DIAGRAMS , Refrigerated Console for schematic and connector information.
Normal Operation

When the ignition switch is in the RUN or ACCESSORY position, voltage is supplied to the refrigerator relay
coil from Smart Junction Box (SJB) fuse 34 (5A), through circuit CBP34 (VT/BN). The refrigerator relay coil is
grounded at all times through circuit GD120 (BK/GN). High current voltage is supplied to the refrigerator relay
from Battery Junction Box (BJB) fuse 15 (15A), through circuit SBB15 (WH/RD). When the refrigerator relay
is activated, voltage is supplied to the refrigerator through circuit CBB15 (BN/BU). The refrigerator is
grounded through circuit GD149 (BK/GY).
This pinpoint test is intended to diagnose the following:
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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex







Fuse(s)
Refrigerator relay
Refrigerator switch
Refrigerator
Wiring, terminals or connectors

PINPOINT TEST A: THE REFRIGERATOR DOES NOT OPERATE CORRECTLY

A1 CHECK CIRCUIT CBB15 (BN/BU) FOR VOLTAGE
 Disconnect: Refrigerator C3415.
 Ignition ON.
 Measure the voltage between refrigerator C3415-1, circuit CBB15 (BN/BU), harness side and
ground.

Fig. 1: Measuring Voltage Between Refrigerator C3415-1, Circuit CBB15 (BN/BU), Harness
Side And Ground
Courtesy of FORD MOTOR CO.
Is the voltage greater than 10 volts?
Yes : GO to A6.
No : GO to A2.
A2 CHECK THE REFRIGERATOR RELAY
 Ignition OFF.
 Disconnect: Refrigerator Relay.
 Carry out the Relay component test for the BJB refrigerator relay.


Refer to SYSTEM WIRING DIAGRAMS for component testing.
Did the refrigerator relay pass the component test?
Yes : GO to A3.
No : INSTALL a new refrigerator relay. TEST the system for normal operation.
A3 CHECK CIRCUIT CBP34 (VT/BN) FOR VOLTAGE
 Ignition ON.


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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex



Measure the voltage between BJB refrigerator relay pin 1, circuit CBP34 (VT/BN), harness side
and ground.

Fig. 2: Measuring Voltage Between BJB Refrigerator Relay Pin 1, Circuit CBP34 (VT/BN),
Harness Side And Ground
Courtesy of FORD MOTOR CO.
Is the voltage greater than 10 volts?
Yes : GO to A4.
No : VERIFY SJB fuse 34 (5A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the
appropriate SystemWiring Diagrams to identify the possible causes of the circuit short. TEST the
system for normal operation.
A4 CHECK CIRCUIT SBB15 (WH/RD) FOR VOLTAGE
 Measure the voltage between BJB refrigerator relay pin 3, circuit SBB15 (WH/RD), harness side
and ground.


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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Fig. 3: Measuring Voltage Between BJB Refrigerator Relay Pin 3, Circuit SBB15 (WH/RD),
Harness Side And Ground
Courtesy of FORD MOTOR CO.
Is the voltage greater than 10 volts?
Yes : GO to A5.
No : VERIFY BJB fuse 15 (15A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the
appropriate System Wiring Diagrams to identify the possible causes of the circuit short. TEST the
system for normal operation.
A5 CHECK FRONT WIPER RELAY CIRCUIT GD120 (BK/GN) FOR GROUND
 Measure the resistance between BJB refrigerator relay pin 2, circuit GD120 (BK/GN) and ground.


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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Fig. 4: Measuring Resistance Between BJB Refrigerator Relay Pin 2, Circuit GD120 (BK/GN)
And Ground
Courtesy of FORD MOTOR CO.
Is the resistance less than 5 ohms?
Yes : REPAIR open in circuit CBB15 (BN/BU). TEST the system for normal operation.
No : REPAIR open in circuit GD120 (BK/GN). TEST the system for normal operation.
A6 CHECK CIRCUIT GD149 (BK/GY) FOR AN OPEN
 Ignition OFF.
 Measure the resistance between refrigerator C3415-3, circuit GD149 (BK/GY), harness side and
ground.


Fig. 5: Measuring Resistance Between Refrigerator C3415-3, Circuit GD149 (BK/GY),
Harness Side And Ground
Courtesy of FORD MOTOR CO.
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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Is the resistance less than 5 ohms?
Yes : GO to A7.
No : REPAIR the circuit(s). TEST the system for normal operation.
A7 CHECK THE REFRIGERATOR SWITCH
 Remove the refrigerator switch. Refer to REFRIGERATOR SWITCH.
 Carry out the Refrigerator Switch Component Test.
 Did the refrigerator switch pass the component test?
Yes : GO to A8.
No : INSTALL a new refrigerator switch.
A8 CHECK FOR CORRECT REFRIGERATOR OPERATION
 Disconnect all refrigerator connectors.
 Check for:
 corrosion.
 pushed-out pins.
 Connect all the refrigerator connectors and make sure they seat correctly.
 Operate the system and verify the concern is still present.
 Is the concern still present?
Yes : INSTALL a new refrigerated rear floor console. REFER to CONSOLE - REAR, FLOOR.
No : The system is operating correctly at this time. Concern may have been caused by a loose or
corroded connector. TEST the system for normal operation.


Component Test
Refrigerator Switch

Fig. 6: Identifying Refrigerator Switch
Courtesy of FORD MOTOR CO.
REFRIGERATOR SWITCH REFERENCE CHART
Connect Self-Powered Test Light or Ohmmeter to Move Switch to this
Terminals
Position
1 and 2
COOL

A Good Switch will
Indicate
Closed

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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

1 and 3
1 and 4
1 and 5
1 and 6
2 and 3
2 and 4
2 and 5
2 and 6
3 and 4
3 and 5
3 and 6
4 and 5
4 and 6
5 and 6

FREEZE
-

Open
Open
Open
Closed
Open
Open
Open
Open
Open
Open
Open
Open
Open
Open

REMOVAL AND INSTALLATION
INSTRUMENT PANEL - EXPLODED VIEW
Instrument Panel Finish Panels and Fasteners

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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Fig. 7: Exploded View Of Instrument Panel With Torque Specifications
Courtesy of FORD MOTOR CO.
WINDOW MOULDING - REAR QUARTER
Item
Part Number
Description
1
W709178
Instrument panel upper cowl bolt (3 required)
2
04480 RH/ 04481 LH Instrument panel side trim panel
3
W712210
Instrument panel side finish panel retaining clip (5 required per side)
4
W712961
Steering column shaft-to-steering column bolt
5
W710259
Instrument panel side bolt (6 required)
6
W709268
Instrument panel center support bracket bolt (4 required)
Instrument Panel Trim Panels, Finish Panels and Electrical Connectors

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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Fig. 8: Identifying Instrument Panel Trim Panels, Finish Panels And Electrical Connectors
Courtesy of FORD MOTOR CO.
WINDOW MOULDING - REAR QUARTER
Item Part Number
Description
1
N808453
Steering column opening trim panel screw (3 required)
2
04459
Steering column opening trim panel
3
W712210
Steering column opening trim panel retaining clip (3 required)
4
LH instrument panel electrical connector (part of 14401)
5
Lower LH instrument panel electrical connectors (part of 14401)
6
Small RCM electrical connector (part of 14401)
7
RH instrument panel electrical connector (part of 14401)
8
18812A
Antenna cable
9
04338
RH Instrument panel finish panel
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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

10
11
12

W712210
04339
W712210

RH Instrument panel finish panel retaining clip (8 required)
LH Instrument panel finish panel
LH Instrument panel finish panel retaining clip (2 required)

Instrument Panel and Instrument Cluster Finish Panels

Fig. 9: Identifying Instrument Panel And Instrument Cluster Finish Panels
Courtesy of FORD MOTOR CO.
REMOVAL AND INSTALLATION
Item Part Number
Description
1
W707628
Center instrument panel finish panel screw (6 required)
2
04302
Center instrument panel finish panel
3
W712210
Center instrument panel finish panel retaining clip (7 required)
4
Instrument cluster finish panel screw covers (part of 044D70)
5
W707628
Instrument cluster finish panel screw (3 required)
6
044D70
Instrument cluster finish panel
7
W712210
Instrument cluster finish panel retaining clip (3 required)
8
13A018
Light sensor
9
Light sensor electrical connector (part of 14401)
10
044E82
Instrument panel defroster grille
11
W712210
Instrument panel defroster grille retaining clip (14 required)
Instrument Panel Upper Section
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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Fig. 10: Identifying Instrument Panel Upper Section
Courtesy of FORD MOTOR CO.
TIGHTENING TORQUE SPECIFICATIONS
Item
Part Number
Description
1
W505424
Hood release handle bolt
2
16916
Hood release handle
3
W707628
Instrument panel upper section screw (13 required)
4
04320
Instrument panel upper section
5
04545
In-vehicle crossbeam
1. For additional information, refer to the appropriate procedures.
INSTRUMENT PANEL
Removal

1. Rotate the steering wheel until the front wheels are in the straight-ahead position.
2. Drain the coolant. For additional information, refer to ENGINE COOLING .
3. Recover the refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM GENERAL INFORMATION AND DIAGNOSTICS .
4. Remove the wiper mounting arm and pivot shaft assembly. For additional information, refer to WIPERS
AND WASHERS .
5. Disconnect the 3 PCM electrical connectors.
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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

6. Remove the wire harness retainer from the PCM bracket stud.

Fig. 11: Locating Wire Harness Retainer Of PCM Bracket Stud
Courtesy of FORD MOTOR CO.
7. Remove the 2 nuts and the PCM.

Fig. 12: Locating PCM Nuts
Courtesy of FORD MOTOR CO.
8. Remove the 3 nuts and the PCM bracket.

Fig. 13: Locating PCM Bracket Nuts
Courtesy of FORD MOTOR CO.
9. Remove the vacuum hose clip from the strut tower cross brace.
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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Fig. 14: Locating Vacuum Hose Clip
Courtesy of FORD MOTOR CO.
10.

NOTE:

LH side shown in illustration, RH side similar.

Remove the strut tower cross brace.


Remove the LH and RH strut upper mount inboard nuts.

Fig. 15: Locating Strut Upper Mount Inboard Nuts
Courtesy of FORD MOTOR CO.
11. Remove the vacuum hose and the evaporator purge solenoid hose from the upper intake manifold and
position aside.

Fig. 16: Locating Vacuum Hose And Evaporator Purge Solenoid Hose
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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Courtesy of FORD MOTOR CO.
12. Remove the crankcase vent tube and the vacuum tube from the Air Cleaner (ACL) outlet pipe.

Fig. 17: Locating Crankcase Vent Tube And Vacuum Tube
Courtesy of FORD MOTOR CO.
13. Loosen the ACL outlet pipe-to-Throttle Body (TB) clamp and the ACL outlet pipe-to- ACL cover clamp.

Fig. 18: Locating ACL Outlet Pipe-To-Throttle Body Clamp And ACL Outlet Pipe-To- ACL Cover
Clamp
Courtesy of FORD MOTOR CO.
14. Remove the ACL outlet pipe.
15. Remove the heater hoses from the heater hose separator.

Fig. 19: Locating Heater Hoses
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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

Courtesy of FORD MOTOR CO.
16. Remove the heater hoses from the heater hose tubes and position aside.

Fig. 20: Locating Heater Hoses Clamp
Courtesy of FORD MOTOR CO.
17. Remove the heater hoses from the heater core and position aside.

Fig. 21: Locating Heater Hoses Clamp
Courtesy of FORD MOTOR CO.
18. Remove the Thermostatic Expansion Valve (TXV) manifold bolt and the TXV manifold.
 Discard the O-ring seals.

Fig. 22: Locating Thermostatic Expansion Valve Manifold Bolt
Courtesy of FORD MOTOR CO.
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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

19.
20.
21.
22.
23.
24.
25.
26.
27.
28.

Remove the RH and LH instrument panel upper cowl bolts.
Remove the steering wheel. For additional information, refer to STEERING COLUMN .
Remove the front seats. For additional information, refer to SEATING .
Remove the front floor console. For additional information, refer to CONSOLE - FRONT, FLOOR.
Remove the LH and RH front door scuff plate trim panels.
 Lift the scuff plate trim panels upward to release the retaining clips.
Remove the LH and RH front door opening weatherstrips.
Remove the LH and RH A-pillar trim panels. For additional information, refer to INTERIOR TRIM
AND ORNAMENTATION .
Remove the LH and RH instrument panel side trim panels.
 Pull the instrument panel side trim panels outward to release the retaining clips.
Remove the LH and RH lower cowl trim panels.
 Pull the lower cowl trim panels rearward to release the retaining clips.
Remove the hood release handle bolt and position aside the hood release handle.

Fig. 23: Locating Hood Release Handle Bolt
Courtesy of FORD MOTOR CO.
29. Disconnect the LH instrument panel bulkhead electrical connector.

Fig. 24: Locating LH Instrument Panel Bulkhead Electrical Connector
Courtesy of FORD MOTOR CO.
30. Disconnect the 2 Smart Junction Box (SJB) lower electrical connectors and the lower bulkhead electrical
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© 2006 Mitchell Repair Information Company, LLC.

2009 Ford Flex SE
2009 ACCESSORIES & BODY, CAB Instrument Panel and Console - Flex

connector.

Fig. 25: Locating Smart Junction Box Lower Electrical Connectors And Lower Bulkhead Electrical
Connector
Courtesy of FORD MOTOR CO.
31. Remove and discard the steering column shaft-to-steering column bolt.

Fig. 26: Locating Steering Column Shaft-To-Steering Column Bolt
Courtesy of FORD MOTOR CO.
32. Detach the steering column shaft from the steering column.
33. Remove the driver footrest pad.
 Remove the 2 pin-type retainers.

Fig. 27: Locating Pin-Type Retainers
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© 2006 Mitchell Repair Information Company, LLC.

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