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Side Air Bag Module: Removal

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
  1. Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment.
  2. Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment.
  3. Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment.
  4. After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards.
  5. Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury.
  6. Side air bag modules with damaged covers must be replaced.
  7. Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced. Cleaning is permissible.
  8. To reduce the risk of personal injury, do not use any memory saver devices.
CAUTION: It is necessary to rezero the occupant classification sensor (OCS) system when a front passenger seat cushion is disassembled, a new trim cover is installed, or an OCS service kit is installed. A diagnostic tool is used to trigger the active command to carry out rezeroing of the OCS system.
NOTE:
  1. If a side air bag deployment took place, a new seat back pad, trim cover, and side air bag module must be installed. The seat back frame should be replaced if necessary.
  2. When replacing the side air bag after deployment, refer to SEATING for additional information concerning the installation of a new side air bag.
  3. The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
  4. The driver seat side air bag module is shown, the passenger side is similar.
  5. Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again.

    All seats 

  1. Position the seat to access all the seat track-to-floor pan bolts and the safety belt anchor.
  2. Depower the system. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING .
  3. Remove the front seat. For additional information, refer to SEATING .

    4. Seats with manual recline 

  4. Pull out and remove the manual recline handle.

    5. Seats with power 

  5. Remove the power seat switch knobs.

    6. All seats 

  6. Remove the rear screw, pull out on the side and front and separate the side shield.
    • Vehicles with manual seats, remove the side shield.

    7. Seats with power 

  7. Remove the power seat control switch and remove the side shield.

    8. All seats 

  8. Release the rear seat cushion trim cover J-clip.
  9. Release the hook and loop strip at the rear of the seat cushion trim cover.
  10. Disconnect the side air bag module electrical connector.
  11. Release the side air bag module wire routing clips.
    Fig 1: Locating Side Air Bag Module Wire Routing Clips
    G04659742Courtesy of FORD MOTOR CO.

    12. Seats with manual lumbar adjust 

  12. Remove the manual lumbar handle.
    • On driver seat, remove the clip and manual lumbar handle.
    • On passenger seat, remove the screw and the manual lumbar handle.

    13. All seats 

  13. Release the seat back lower trim cover J-clip.
    14. WARNING: Front seat back trim covers installed on seats equipped with side air bags cannot be repaired; they are to be replaced (cleaning is permissible).
    CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam.
  14. Place a hand between the seat backrest trim cover and foam pad and carefully separate the hook and loop strips, then carefully roll up the seat back trim cover in an inside out fashion to the first row of hog rings in the front.
    • On passenger seat, pull the backrest fold flat nylon release strap through the trim cover bezel opening.
  15. Remove the first row of hog rings.
    Fig 2: Locating Hog Rings (1 Of 2)
    G04659743Courtesy of FORD MOTOR CO.
  16. Release the hook and loop strips and carefully roll up the seat back trim cover to the second row of hog rings in the front.
    Fig 3: Locating Hog Rings (2 Of 2)
    G04659744Courtesy of FORD MOTOR CO.
  17. Release the J-clips at the back of the trim cover.
    Fig 4: Locating J-Clips
    G04659745Courtesy of FORD MOTOR CO.
  18. Release the side air bag module backrest trim cover chute J-clip from around the side air bag module cover.
    Fig 5: Locating Side Air Bag Module Backrest Trim Cover Chute J-Clip
    G04659746Courtesy of FORD MOTOR CO.
  19. Feed the side air bag module backrest trim cover chute and J-clip retainer out through the side air bag module backrest foam pad opening.
    Fig 6: Locating J-Clip Retainer Out Through Side Air Bag Module Backrest Foam Pad Opening
    G04659747Courtesy of FORD MOTOR CO.
  20. Release the hook and loop strip, and then invert the trim cover to the third row of hog rings front and rear and remove the hog rings (backside hog rings shown).
    Fig 7: Locating Hog Rings (1 Of 2)
    G04659748Courtesy of FORD MOTOR CO.
    21. NOTE: Vehicles with manual lumbar adjust shown.
    Fig 8: Locating Hog Rings (2 Of 2)
    G04659749Courtesy of FORD MOTOR CO.
  21. Remove the hog rings attaching the lumbar basket (if equipped) or backrest support (if equipped) and foam pad to the backrest frame and then position the foam pad aside.
    22. NOTE:
    1. Seat backrest trim cover and foam are removed for clarity.
    2. Note the routing of the side air bag module wiring for installation.
    Fig 9: Locating Side Air Bag Module Wire Routing Clips
    G04659750Courtesy of FORD MOTOR CO.
  22. Release the side air bag module wire routing clips.
  23. Remove the 2 nuts and the side air bag module.
    Fig 10: Locating Side Air Bag Module Nuts
    G04659751Courtesy of FORD MOTOR CO.
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