Attachment III - Supplement # 1

AFFECTED VEHICLES:
1992-1997 MODEL YEAR AEROSTAR

SERVICE PROCEDURE





Use the following Service Procedure to install a relay wiring harness into the ignition switch electrical connector. See Figure 1.

NOTE:
The following test will establish a baseline for the verification test at the end of this Service Procedure.

1. Start the engine and perform the following:

^ Turn the blower motor to HIGH.

^ Turn the radio on.

^ On vehicles equipped with automatic transmission, check brake shift interlock system by trying to shift from Park to any other gear without depressing the brake pedal.

2. Record the radio stations, then disconnect the battery negative cable.

3. Remove the knee bolster.





4. Remove the instrument panel reinforcing panel. See Figure 2.





5. Completely loosen the ignition switch electrical connector retaining screw, then disconnect the ignition switch electrical connector. See Figure 3.





6. Remove the ignition switch electrical connector wiring shield and terminal locking plate. See Figure 4.





7. Remove the gray/yellow wire, circuit 687, from terminal A3 of the ignition switch electrical connector. See Figure 5.





8. Install the black/light green wire of "jumper A" into terminal A3 of the ignition switch electrical connector. See Figure 6.





9. Install the gray/yellow wire, circuit 687, into the open slot of "Jumper A" connector. See Figure 7.





10. Remove the yellow wire, circuit 37, from terminal B2 of the ignition switch electrical connector. See Figure 8.





11. Install the yellow wire, circuit 37, into the loose, 2-way connector in the slot opposite the key way. See Figure 9.





12. Remove the gray/yellow wire, circuit 687, from terminal A2 of the ignition switch electrical connector. See Figure 10.





13. Install the gray/yellow wire, circuit 687, into the loose, 2-way connector in the slot next to the key way. See Figure 11.

14. Install the ignition switch electrical connector wiring shield and terminal locking plate.

15. On manual transmission equipped vehicles, locate the unused brake shift lock solenoid electrical connector within the ignition switch wiring harness (under the paper tape). Access the electrical connector by tearing the paper tape (using fingers) on the wiring harness approximately 30 mm (1 inch) from the back of the ignition switch connector.





16. On automatic transmission equipped vehicles, disconnect the electrical connector from the brake shift lock solenoid. See Figure 12.

NOTE:
Steps 17-23 apply to both manual and automatic transmission equipped vehicles.

17. Remove the locking wedge from the brake shift lock solenoid electrical connector.





18. Remove the black wire, circuit 57, from the center terminal of the brake shift lock solenoid electrical connector. See Figure 13.





19. Install the black wire of "Jumper B" into the center terminal of the brake shift lock solenoid electrical connector. See Figure 14.

20. Install the locking wedge into the brake shift lock solenoid electrical connector.

21. Remove the locking wedge from the "Jumper B" electrical connector.





22. Install the black wire, circuit 57 (removed from the brake shift lock solenoid electrical connector) into either open slot of "Jumper B." See Figure 15.

23. Install the locking wedge into the "Jumper B" electrical connector.

24. On manual transmission equipped vehicles, reposition the brake shift lock solenoid electrical connector within the wiring harness and rewrap the harness with electrical tape.

25. On automatic transmission equipped vehicles, connect the electrical connector to the brake shift lock solenoid.

26. Install the ignition switch electrical connector. Tighten the retaining screw securely.





27. Connect the relay harness to the three (3) open electrical connectors. Connector halves will only mate with their correct opposite halves. See Figure 16.





28. Using foam tape, wrap both gray electrical connectors together. See Figure 17.


29. Using foam tape, wrap the black electrical connector. See Figure 17.





30. Using tie straps on the relay harness, secure the relay harness as shown in Figure 18. Make sure the relay is accessible for service.

NOTE:
Make sure that the harness is away from all moving parts. See Figure 18.

31. Trim the tie straps.

32. Install the instrument panel reinforcing panel. Tighten the retainers to 10-14 Nm (7-10 lb-ft).

33. Install the knee bolster.

34. Connect the battery negative cable.

35. Start the engine and verify the modification as follows:

- Turn the blower motor to HIGH.

- Turn the radio on.

- On vehicles equipped with automatic transmission, check the brake shift interlock system by trying to shift from Park to any other gear without depressing the brake pedal.

NOTE:
If any of the above components were working before the modification and are not working now, repeat the Service Procedure.

36. Turn the ignition key to the accessory position, then turn the blower motor to HIGH. If the blower motor operates in the accessory position, repeat the Service Procedure.

37. Program the radio stations.