Ford Explorer: Voltage Converter/Inverter / Removal and Installation - Direct Current/Direct Current (DC/DC) Converter Control Module

Removal

  WARNING: Disconnect the 12 volt battery before servicing the direct current to alternating current (DC-AC) inverter or alternating current (AC) powerpoint to prevent the risk of high voltage shock. Failure to follow this instruction may result in serious personal injury.

1. NOTE: If installing a new module, it is necessary to upload the module configuration information to the scan tool prior to removing the module. This information must be downloaded into the new module after installation.

   Upload the Direct Current/Direct Current (DC/DC) configuration to the scan tool by following the scan tool on-screen instructions.
   

1. Disconnect the battery negative terminal.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. De-energize the high voltage system.
   Refer to: High Voltage System De-energizing (414-03 High Voltage Battery, Mounting and Cables, General Procedures).
   

1. Remove the PCM.
   Refer to: Powertrain Control Module (PCM) (303-14C Electronic Engine Controls - 3.3L Duratec-V6/3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
   

1. Remove the front RH headlamp assembly.
   Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   

1. Detach the wiring harness retainers and position aside the harness.
   

1. Detach the wiring harness retainers and position aside the harness.
   

1. Remove the bolts and the PCM bracket.
   Torque: 53 lb.in (6 Nm)

1. Disconnect the Direct Current/Direct Current (DC/DC) converter control module electrical connectors.
   

1. Remove the coolant hoses.
   

1. Position aside the battery terminal cover.
   

1. Disconnect the battery positive terminal.
   Torque: 159 lb.in (18 Nm)

1. 
   
   1. Remove the retainers.
      Torque: 53 lb.in (6 Nm)
   2. Remove the retainers.
      Torque: 159 lb.in (18 Nm)

1. Disconnect the horn electrical connector.
   

1. Remove the bolt and the horn assembly.
   Torque: 26 lb.ft (35 Nm)

1. NOTE: Lower right-hand side DC/DC converter control module to bracket fastener accessed through horn slot.

   Remove the fasteners and the DC/DC converter control module.
   Torque: 53 lb.in (6 Nm)

Installation

1. To install, reverse the removal procedure.
   

1. If replacing the module, download the Direct Current/Direct Current (DC/DC) converter control module configuration information from the scan tool to the new Direct Current/Direct Current (DC/DC) converter control module following the scan tool on-screen instructions.
   

1. Bleed the cooling system.
   Refer to: Cooling System Filling and Bleeding (303-03E Electric Powertrain Cooling - 3.3L Duratec-V6 – Hybrid (BP), General Procedures).