Ford Falcon. Manual — part 480

501-20b-135

Occupant Restraints — Passive

501-20b-135

GENERAL PROCEDURES (Continued)

5. Set up for the positioning of the weld nut.

10. Tighten the attaching screws to specification. For

additional information, refer to Specifications in

1. Route a sufficient length of wire through the

this section.

weld nut clearance hole and back out an

adjacent access hole.

Weld Nut Repair — Stripped Weld Nut

2. Position a weld nut, shoulder end up, onto the

wire.

WARNING: To avoid accidental deployment

3. Position a flat washer onto the wire and

and possible personal injury, the backup power

secure it so it cannot be pulled off.

supply must be depleted before repairing or

replacing any front or side airbag supplemental

restraint system (SRS) components and before

servicing, replacing, adjusting or striking

components near the front or side airbag sensors,

such as doors, instrument panel, console, door

latches, strikers, seats and hood latches.

The side impact sensors (if equipped) are located

at or near the base of the B-pillars.

To deplete the backup power supply energy,

disconnect the battery ground cable and wait at

least one minute. Be sure to disconnect auxiliary

batteries and power supplies (if equipped).
1. Inspect the weld nut and surrounding area for

repair.

If there is not enough clearance for a larger

bolt stud to go through or a larger bolt head to

Item

Description

turn, then a Heli-Coil® will have to be made.

1

Cord

Follow the instructions with the Heli-Coil®

2

Weld nut

repair kit.

3

Flat Washer

2. If a 6 mm weld nut is stripped, drill out the hole

using a letter “H” or 6.5mm (0.26in) drill bit. Then

6. Plug weld the weld nut into position.

tap, using an 8mm by 1.25 bit.

1. Pull the welding wire back through the

Do not oversize a 6 mm weld nut by more

clearance hole, allowing the weld nut and flat

than 8mm.

washer to follow the welding wire through and

stop against the sheet metal.

3. If an 8 mm weld nut is stripped, drill the hole

using a letter “R” or in 9.75mm (0.3990) drill bit.

2. Make sure the weld nut shoulder is aligned

Then tap, using a 10mm by 1.50 bit.

through the clearance hole in the sheet metal.

Do not oversize an 8 mm weld nut by more

3. With the weld nut firmly held in position, plug

than 10 mm.

weld the weld nut at the three holes drilled

previously.

4. Obtain the appropriate oversized screw.
5. Install the attaching screw(s) to the component.
6. Tighten the attaching screws to specification. For

additional information, refer to Specifications in

this section.

7. Metal finish as required.
8. Verify the nut is securely in place.
9. Install the component with the previously obtained

screw.

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501-20b-136

Occupant Restraints — Passive

501-20b-136

REMOVAL AND INSTALLATION

1. Disconnect the battery ground cable (14301) and

Front Impact Severity Sensor

wait at least one minute. For additional

information, refer to Section 414-01.

Special Tool(s)

WARNING: To reduce the risk of serious

Diagnostic Tool, Restraint

personal injury, read and follow all warnings,

System (2 req’d)

cautions, notes, and instructions in the

418-F395 (014-R1079)

supplemental restraint system (SRS)

deactivation/reactivation procedure.

2. Deactivate the supplemental restraint system

(SRS). For additional information, refer to

Supplemental Restraint System (SRS)

Diagnostic Tool, Restraint

Deactivation and Reactivation in the General

System (4 req’d)

Procedures portion of this section.

418-F403

Remove scrivets and remove the modesty panel.

3. Remove the pin-type retainers and pull the lower

grill opening shroud back, creating an opening to

access the front impact severity sensor.

Diagnostic Tool, Restraint

System (2 req’d)

418-F088 (105-R0012)

Removal

WARNING: Vehicle sensor orientation is

critical for proper system operation. If a vehicle

equipped with an airbag supplemental restraint

system (SRS) is involved in a collision, inspect

the sensor mounting bracket and wiring pigtail for NOTE: The front impact severity sensor is mounted

deformation. Replace and properly position the

under the lower radiator support.

sensor or any other damaged supplemental

4. Remove the front impact severity sensor and

restraint system (SRS) components whether or

bracket.

not the airbag is deployed.

1. Remove the bolts.

WARNING: To avoid accidental deployment

2. Disconnect and remove the front impact

and possible personal injury, the backup power

severity sensor and bracket.

supply must be depleted before repairing or

replacing any front or side airbag supplemental

restraint system (SRS) components and before

servicing, replacing, adjusting or striking

components near the front or side airbag sensors,

such as doors, instrument panel, console, door

latches, strikers, seats and hood latches.

The side airbag sensors are located at or near the

base of the B-pillars.

To deplete the backup power supply energy,

disconnect the battery ground cable and wait at

least one minute. Be sure to disconnect auxiliary

batteries and power supplies (if equipped).
NOTE: Repair is made by installing a new part only. If

the new part does not correct the condition, install the

original part and perform the diagnostic procedure

Item

Description

again.

1

Bolt

2

Front impact severity sensor

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501-20b-137

Occupant Restraints — Passive

501-20b-137

REMOVAL AND INSTALLATION (Continued)

Item

Description

4. Disconnect the battery ground cable and wait at

least one minute. For additional information, refer

3

Electrical connector

to Section 414-01.

Installation

5. Position the lower grill opening shroud and install

the pin-type retainers

WARNING: To reduce the risk of serious

Position the modesty panel trim over the latch and

personal injury, read and follow all warnings,

secure with scrivets.

cautions and notes at the beginning of the

removal procedure.
NOTE: Make sure the negative battery cable is still

disconnected before continuing with the installation

portion of this procedure.

NOTE: Make sure the lower radiator support and front

impact severity sensor bracket mating surfaces are

clean and debris free.

1. Install the front impact severity sensor.

1. Connect the front impact severity sensor.

2. Position the front impact severity sensor and

bracket so the locator tab goes into the lower

radiator support opening and the sensor

bracket sits flat up against the support.

3. Install the bolts.

WARNING: To reduce the risk of serious

personal injury, read and follow all warnings,

cautions, notes, and instructions in the

supplemental restraint system (SRS)

deactivation/reactivation procedure.
6. Reactivate the supplemental restraint system

(SRS). For additional information, refer to

Supplemental Restraint System (SRS)

Deactivation and Reactivation in the General

Procedures portion of this section.

WARNING: The restraint system

diagnostic tool is for restraint system service

only. Remove from the vehicle prior to road

use. Failure to remove could result in injury

and possible violation of vehicle safety

standards.

Item

Description

7. With all the restraint system diagnostic tools

1

Bolt

removed, prove out the supplemental restraint

2

Front impact severity sensor

system (SRS). For additional information, refer to

Airbag and Safety Belt Pretensioner Supplemental

3

Electrical connector

Restraint System (SRS), in the Diagnosis and

2. Connect the battery ground cable. For additional

Testing portion of this section.

information, refer to Section 414-01.

3. With the restraint system diagnostic tools installed

at all deployable devices, prove out the

supplemental restraint system (SRS). For

additional information, refer to Airbag and Safety

Belt Pretensioner Supplemental Restraint System

(SRS), in the Diagnosis and Testing portion of this

section.

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501-20b-138

Occupant Restraints — Passive

501-20b-138

REMOVAL AND INSTALLATION (Continued)

NOTE: The right-hand drive passenger side is shown,

Side Impact Sensor — First Row, B —

all others are similar.

Pillar

1. Disconnect the battery ground cable (14301) and

wait at least one minute. For additional

Special Tool(s)

information, refer to Section 414-01.

Diagnostic Tool, Restraint

System (2 req’d)

WARNING: To reduce the risk of serious

418-F395 (014-R1079)

personal injury, read and follow all warnings,

notes, and instructions in the supplemental

restraint system (SRS)

deactivation/reactivation procedure.

2. Deactivate the supplemental restraint system

(SRS). For additional information, refer to

Diagnostic Tool, Restraint

Supplemental Restraint System (SRS)

System (4 req’d)

Deactivation and Reactivation in the General

418-F403

Procedures portion of this section.

3. Remove the B-pillar trim panel. For additional

information, refer to Section 501-05.

Diagnostic Tool, Restraint

System (2 req’d)

418-F088 (105-R0012)

Removal

WARNING: Vehicle sensor orientation is

critical for correct system operation. If a vehicle

equipped with an airbag supplemental restraint

system (SRS) is involved in a collision, inspect

Item

Description

the sensor mounting bracket and wiring pigtail for

deformation. Replace and correctly position the

1

B-Pillar side impact sensor

sensor or any other damaged supplemental

2

Screw

restraint system (SRS) components whether or

not the airbag is deployed.

WARNING: To avoid accidental deployment

and possible personal injury, the backup power

supply must be depleted before repairing or

replacing any front or side airbag supplemental

restraint system (SRS) components and before

servicing, replacing, adjusting or striking

components near the front or side airbag sensors,

such as doors, instrument panel, console, door

latches, strikers, seats and hood latches.

The side impact sensors (if equipped) are located

at or near the base of the B-pillars.

To deplete the backup power supply energy,

disconnect the battery ground cable and wait at

least one minute. Be sure to disconnect auxiliary

batteries and power supplies (if equipped).
NOTE: Repair is made by installing a new part only. If

the new part does not correct the condition, install the

original part and perform the diagnostic procedure

again.

G12360 en